Backflushing in SAP PP is a crucial concept in SAP Production Planning (PP) that streamlines the goods issue process during production. It refers to the automatic deduction of component quantities from inventory when a production order is confirmed, eliminating the need for manual goods issue transactions. This tutorial will guide you through the concept of backflushing, how to set it up in SAP, and the hierarchy of activation in master data objects.

Introduction to Backflushing in SAP PP

Backflushing is an automated process in SAP PP where the system automatically posts the goods issue for components at the time of order confirmation. This means that when you confirm the production order or operation, SAP automatically deducts the component quantities from inventory without the need for a separate goods issue transaction.

Key Points:

  • Automated Goods Issue: Eliminates manual posting.
  • Triggered at Confirmation: Occurs when you confirm production activities.
  • Reduces Administrative Tasks: Streamlines the production process.

Benefits of Backflushing

Implementing backflushing offers several advantages:

  • Efficiency: Speeds up the production process by reducing manual data entry.
  • Accuracy: Minimizes human errors associated with manual postings.
  • Simplified Inventory Management: Automatically adjusts inventory levels.
  • Real-Time Updates: Provides up-to-date inventory information.

Activation Hierarchy

Backflush can be activated in multiple master data objects within SAP. The system checks for the backflush indicator based on the following hierarchy, giving priority to the highest level:

  1. Routing
  2. Material Master
  3. Work Center

1 Routing

In the Routing, backflush is set at the component assignment level. This allows you to specify backflushing for individual components associated with specific operations.

  • Highest Priority: Settings here override those in the material master and work center.
  • Flexibility: Control backflush at a granular level for each component and operation.

2 Material Master

In the Material Master, the backflush indicator can be activated for each material.

  • Option to Delegate: You can choose to let the work center decide by not setting the indicator.
  • Material-Specific Control: Applies to all uses of the material unless overridden by routing.

3 Work Center

In the Work Center, you can activate backflush for all components consumed at that work center.

  • Default Setting: If neither the routing nor the material master specifies backflush, the system refers to the work center.
  • Advantage: Convenient when you want all components processed at a work center to be backflushed without setting each one individually.

Note: The system follows this hierarchy when determining whether to backflush a component. If backflush is set in the routing, it takes precedence over settings in the material master and work center.

Setting Up Backflushing

In the Routing

To activate backflush for a component in routing:

  1. Access Routing Transaction: Use Transaction CA01 (Create Routing) or CA02 (Change Routing).
  2. Select Operation: Choose the operation where the component is assigned.
  3. Component Assignment: Navigate to the Component Allocation screen.
  4. Set Backflush Indicator:
  • Locate the component.
  • Set the Backflush checkbox for that component.

Example:

ComponentOperationBackflush
COMP10010Yes
COMP20020No

In the Material Master

To activate backflush in the material master:

  1. Access Material Master: Use Transaction MM01 (Create Material) or MM02 (Change Material).
  2. Select Views: Choose the MRP2 or Work Scheduling view.
  3. Set Backflush Indicator:
  • Locate the Backflush field.
  • Set it to indicate that the material is to be backflushed.
  • Alternatively, choose the option to let the work center decide.

Example:

MaterialBackflush Indicator
MAT1Yes
MAT2Work Center Decides

In the Work Center

To activate backflush in the work center:

  1. Access Work Center: Use Transaction CR01 (Create Work Center) or CR02 (Change Work Center).
  2. Basic Data: Navigate to the Default Values tab.
  3. Set Backflush Indicator:
  • Locate the Backflush field.
  • Set it to indicate that components processed at this work center are to be backflushed.

Example:

Work CenterBackflush Indicator
WC1Yes
WC2No

Process Flow of Backflushing

  1. Production Order Creation: A production order is created with components assigned.
  2. Confirmation: The production order or operation is confirmed using Transaction CO11N or CO15.
  3. Automatic Goods Issue:
  • The system checks the backflush indicator based on the hierarchy.
  • Components marked for backflush are automatically issued from inventory.
  1. Inventory Update: Inventory levels for the components are reduced accordingly.
  2. Documentation: Material documents are generated to record the goods issue.

Visual Flow:

Production Order Confirmation
          ↓
   Check Backflush Indicator
          ↓
   Automatic Goods Issue
          ↓
      Inventory Update
          ↓
     Documentation

Conclusion

Backflushing simplifies the production process by automating the goods issue of components during order confirmation. By understanding the activation hierarchy and setting up backflush indicators appropriately in routing, material master, or work center, you can streamline production operations and improve efficiency. Always consider the specific needs of your production environment to determine the best configuration for backflushing.

Further Reading:

  • SAP Help Portal: Backflushing
  • SAP Transaction Codes:
  • CA01 / CA02 – Routing
  • MM01 / MM02 – Material Master
  • CR01 / CR02 – Work Center
  • CO11N / CO15 – Order Confirmation