Work Order Completions and Super Backflush for Kanban

For any source type 1 kanban, regardless of whether it is one-phase or two-phase, you can perform completions for a kanban-generated work order either interactively or blindly at the time that you check in the kanban or mark it as complete. The method that you use to process completions depends on the way in which the processing options are set in the version of the Kanban Processing program (P3157) that you are using. Typically, you use the Kanban Supply version of the Kanban Processing program to check in kanbans for which work orders or rate schedules exist, but you can also use the Kanban Consumption version to perform kanban check-in transactions. However, you must use the Kanban Supply version to perform completion transactions for kanban orders.

Note: You should verify that the processing options of the Kanban Processing program that you are using for check-in and completion transactions are set according to the business process. These versions work independently, and the software processes are dictated by the processing option settings of each version.

You can also use the Super Backflush program (P31123) or the Work Order Completions program (P31114) to process the completion of a kanban-generated work order. This situation will move the status of the Kanban ID from checked out (2) to complete (3). For check-in, you must always use the Kanban Processing program (P3157).

The system enables you to complete a kanban card from work order completions and super backflush, provided that it has these characteristics:

The kanban is a source type 1 one-phase or two-phase kanban.
The kanban is checked out; hence, a work order is associated with the kanban.
The manufacture of the kanban subassembly is completed by the production cell.

When you attempt to complete a work order through work order completions or super backflush, the system determines whether the work order was generated by a kanban transaction. The system performs a backflush (if it is set up to do so), updates inventory for the completed item, updates inventory for the components, initiates the kanban complete transaction, and updates the kanban status to Checked In.

You must set up the bill of material or generated parts list for the kanban work order (or rate schedule) to backflush order inventory. To do this activity, you must use either the B or U issue code type. If you are backflushing work order inventory when the order is complete (using the Completion with Backflush version of the Work Order Completions program), then:

The parts list items must have an issue code type of B.
The work order routing must have at least the last operation step with a pay point code of B or M.

If you are using the Super Backflush program to backflush materials, then:

The parts list items must have an issue code type of U.
The work order routing must have at least the last operation step set up with a pay point code of M or B.
Important: The setup of the system becomes especially critical when you process work order completion activities blindly during kanban complete transactions. If you do not have the proper setup, the system might not account for materials correctly when kanban transactions are processed.