Manufacturing, Distribution, and Internet Applications

[Kennethg]

Our inventory is set to backflush. A new user received goods in and auto issued them. We never auto issue because everything is set to backflush. Now we have Work Orders hung. It won't let me uncheck the backflush in "Work Order maintenance" on those work orders. I'm guessing because they have transactions against them. Now for the big question.. Does anyone know how to undo a Auto Issue? Or does anyone know how to resolve this issue? Thanks!

[tbrasel]

If I read this correctly, the WO is "hung" because there is no material to backflush since it has already been issued to the job.

There are a couple of things to try:

1.  Depending on the version you are on, you might be able to reverse the material issue.   You can find it in the lookup from the Material Issues Activity in Mfg.

2.  If that doesn't work, try to enter a negative material issue for the step that was auto issued.  Process a new Material Issue and enter all the information, but a negative number for the qty.

3.  If that doesn't work, then "adjust in" the part that was auto issued using an inventory transaction.  Depending on how you watch your costs, this may require that you process a cost tier adjustment to correct the FGI cost since the part will have extra material cost associated.  (Also, you may want to offset the Cost Tier Adj to the same GL Account used to process the Inventory Adjustment.  This will help keep the accountants happy.)

Once the material exists, then you should be able to run the backflush.

Hope this helps.

[Kennethg]

Thanks tbrasel! I'll try what you have suggested  and post back.  Thanks Again!

[Kennethg]

I've tried the first 2. The 1st one I'm prompted with, "Reversal Not Allowed!". The second one doesn't work because other work orders have claimed the material and prompts me with, "There is insufficient quantity remaining in WIP for this transaction.". The third one I really don't want to do because it has to much cost associated with it.

I then try to remove the backflush from the material step. In query Anylzer I updated the record to an 'N', but I don't know the repercussion for doing this update. Do you or anyone know if i need to update any other tables or no of a reason why i shouldn't do it? Thanks!

Oh and below is the update statement I used.

UPDATE tmfWorkOrdDetl_HAI SET BackFlush = 'N' WHERE WorkOrderStepKey = 'The WorkOrderStepKey'

[Kennethg]

I have not tried this on the live server only test. I'm waiting to hear what you all think. Also, I realize that I will have to do a few material issues to cover the orders.

[tbrasel]

I don't see why that statement would cause any issues, other than leaving the autoissued parts in WIP, which will end up in the variance account.  I believe the backflush flag is only used when labor is processed and is picked up in that stored procedure to launch the backflush of the material issue.

As always, be careful making SQL changes and run the WO all the way to completion and costing in a test dbase first.

On another note, I would question the 2nd solution a little.  Sounds like some progress or issue steps for the job have been processed so you don't have the total amount remaining in WIP.  Check the open WIP and see what remains, then you can do a negative issue for that many.  (I also think it shows the amount remaining in parenthesis when you get the error while trying to process the negative issue.)  I don't think you can consume the parts from another job, but I haven't looked in that area in a while.

Good Luck!