WO-G , Single part issued , balance of BOM not issued.
WO-I , Go to complete the order, message that all materials not issued. If I say yes to backflush, not only does it backflush the unissued materials it also re-issues the single part that was single issued from WO-G.
 
I have also noticed WO-G will allow you to "pick" the material mutiple times.
 
Does DBA not know when the requirement has been fullfilled ?

>>Does DBA not know when the requirement has been fullfilled ?  
 
Actually, IS Tech has addressed this with a new setting in the SD-B Work Order Defaults for Backflush at Enter Finished Production = B meaning issue only the balance remaining for all components based on the assembly quantity completed.

The "B" setting is for at WO-I, not WO-G so it backflushes whatever hasn't already been issued by sequence after the fact.  You would have already processed the items that get backflushed by sequence by the time you get to WO-I so why doesn't this approach work for you?

Ah...I understand.  We have a default for BOM items to be excluded from scrap backflushing (as in the case of packaging materials and boxes).  maybe there needs to be another one for exclusion from backflushing altogether.

We love backflushing!  We take care of it right now by not putting those lot controlled items in a sequence and only backflushing by sequence for our finished goods type, and only backflush in WO-I with assemblies that have no lot controlled items.  Of course, there is the occasional mistake in which the person finishing production accidentally says yes to backflush for a FG type work order. Really ugly!  So to be able to exclude our lot controlled items from ever being backflushed , however it is accomplished,  would be great!