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WO-I Double material issues when backflushing (Read 1551 times)
Mike_Habich
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WO-I Double material issues when backflushing
05/02/05 at 12:12:35
 
Latest update 3/25/05
 
We always backflush and never issue material to WOs.  Lately we've seen a couple of cases of double material issues.  Two questions:
 
--Is anyone else seeing this (in other words, is it something new)?
 
--This can happen if the user has fat fingers...it's possible to stop partway through the Enter Finished Production procedure, start again, and thus backflush twice while producing only one output assembly.  Can the program be fixed to stop this?
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wildco
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Re: WO-I Double material issues when backflushing
Reply #1 - 05/03/05 at 05:10:39
 
We have had double backflushing recently also.  This seems to come when the receiver receives the parts, but then realizes there was a problem and uses the up arrow to move back up the screen to correct it.  Then, when they cycle through again the backflush repeats.
 
Another issue is that the materials stay in WIP (as shown on IN-A) until the user says Y or N as to whether or not to use STD cost.  the only problem is that often users will leave their station to work on other things during the backflush (as it takes a long time on large BOMs), and mistakenly close the screen without hitting Y or N to the standard cost question.  
 
A fix for either or both issues would be much appreciated, as it would save a lot of time having to fix the records.
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Aaron

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Tim Keating
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Re: WO-I Double material issues when backflushing
Reply #2 - 05/03/05 at 07:35:45
 
I agree that a safeguard would be very desireable.  In my experience, double issues can always be tracked to input error but it should not be that easy to make the error.
 
As a check on this, I review all material transactions daily with an audit report I created in Crystal.  For us its six or seven work order completions so its fairly manageable.  For someone with a large number of daily issues it has to be a big concern.
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Tim Keating
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Re: WO-I Double material issues when backflushing
Reply #3 - 05/03/05 at 08:18:29
 
Quote from Tim Keating   on 05/03/05 at 07:35:45:
I agree that a safeguard would be very desireable.  In my experience, double issues can always be tracked to input error but it should not be that easy to make the error.

 
It is very disheartening how many of these little gotchas are in DBA.  cry  SOP should be that no part of the transaction is committed until all of the transaction variables are validated. It would be better to lose the entire transaction when a problem occurs than to capture part of it and then waste time figuring out what to fix. I understand that the Serial module is separate from the inventory transaction module, but losing the one-to-one relationship between those two bits of data is a big issue in the eyes of our regulators.
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Mike_Habich
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Re: WO-I Double material issues when backflushing
Reply #4 - 05/03/05 at 08:38:45
 
This doesn't even have anything to do with serials.  It's possible to backflush material without creating the assembly.
 
On the basic idea, you're right on target.  No part of the transaction shouldn't be committed until all the input is validated.  This particular problem has been in DBA since at least 2000.
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Re: WO-I Double material issues when backflushing
Reply #5 - 05/03/05 at 09:06:43
 
There is a fundamental problem with the logic here I agree but unfortunately, the backflushing needs to be processed so that the associated component costs can be used in the calculation of the assembly cost.  This is why we developed the "B" default setting in SD-B for backflushing which means "Backflush the balance needed".  That way, if the backflush happens once and the transaction for Enter Finished production is not fully processed, when you go back in to process it again and it attempts to backflush, it will see that no component balances are needed and it wil not process the second backflush.
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Re: WO-I Double material issues when backflushing
Reply #6 - 05/03/05 at 09:07:08
 
Quote from Mike_Habich   on 05/03/05 at 08:38:45:
This particular problem has been in DBA since at least 2000.

 
I would say it's probably been an issue from the very beginning.  It's one of those thing we've all lived with, having made the choice to use a low-budget but all-around pretty decent program.
 
There are dozens of issues like this that IS Tech has addressed and fixed at little expense to subscibers.  Maybe this will be another one.
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Tim Keating
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Mike_Habich
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Re: WO-I Double material issues when backflushing
Reply #7 - 05/03/05 at 12:44:58
 
Fix one problem, create another...
 
If you change default setting to B, if you enter finished production for qty -1 (to disassemble a unit), nothing gets backflushed.
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Tim Keating
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Re: WO-I Double material issues when backflushing
Reply #8 - 05/03/05 at 13:55:37
 
Quote from Mike_Habich   on 05/03/05 at 12:44:58:
If you change default setting to B, if you enter finished production for qty -1 (to disassemble a unit), nothing gets backflushed.

 
I could not live with that, we teardown single items all the time.
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Re: WO-I Double material issues when backflushing
Reply #9 - 05/04/05 at 05:46:02
 
The ultimate problem with what Mike indicated, although he is absolutely right, is that to do so requires the ability to create TEMP tables, or some such solution, during processing and then wipe that info out and transfer the data to the permanent tables. However, in the non-RDBMS environment that is DBA this is a LOT of extra programing effort and has some pretty serious potential data transfer error opportunities.
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Mike_Habich
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Re: WO-I Double material issues when backflushing
Reply #10 - 05/04/05 at 06:23:43
 
It was Colin, not me, who was "absolutely right" about the sequence of posting.  I just said me too...
 
I can certainly live with the B option of checking whether components have been backflushed, as long as negative quantities (disassembly) can be accommodated.
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Re: WO-I Double material issues when backflushing
Reply #11 - 05/04/05 at 07:02:10
 
I agree with Mike, the B option is great, but it should have some capability for negative receipts.
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Aaron

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Re: WO-I Double material issues when backflushing
Reply #12 - 05/04/05 at 07:05:18
 
Ok I get the hint.. I will have a look at the - qty "B" logic.
If its not to bad then it will be in the next Post.. This weekend I hope.
 
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Re: WO-I Double material issues when backflushing
Reply #13 - 05/05/05 at 13:10:36
 
OK, next update will have a change so that if the default is set to B and you are processing a negative, it will act as though the default were set to Y and prompt to backflush and if you say Y it will process negative issues of the components so you can disassemble using negative work order.  
 
We have also disabled the ESC so that once the backflush has happened, you can't get out without completing the full process.  If you realize you made a mistake, you will have to go back in and process a negative.
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wildco
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Re: WO-I Double material issues when backflushing
Reply #14 - 05/06/05 at 05:07:38
 
Thank you very much, this will help immensely.
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Aaron

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