SyteLine Backflush Configuration Guide
Backflushing in SyteLine automatically issues raw materials and components from inventory when production operations are reported complete or when finished goods are received, eliminating the need for manual material issue transactions. Properly configured backflushing reduces shop floor paperwork, speeds up production reporting, and maintains real-time inventory accuracy. Misconfigured backflushing causes phantom inventory, negative balances, and costing errors that compound over time.
Backflush Methods and Item-Level Configuration
SyteLine supports two backflush methods configured at the item level in the Items form's Production tab. The Backflush field offers three options: 'No' (manual issue required), 'When Complete' (material issued when the job operation is reported complete), and 'When Received' (material issued when finished goods are received into inventory). The choice depends on your material tracking requirements and shop floor workflow. 'When Complete' provides operation-level material visibility but requires operators to report each operation completion. 'When Received' is simpler—a single receipt transaction issues all materials—but delays material consumption until the end of the production cycle, hiding WIP accuracy issues. For BOM components, the backflush method is set per material line in the BOM form's Material tab using the Backflush field on the jobmatl record. This allows mixed configurations where expensive or serialized components use manual issue while commodity materials use backflush. Configure the default backflush method in Item Defaults (Menu Path: Master Data > Item Defaults) to avoid setting it manually on every item.
- Three backflush options per item: No (manual), When Complete (operation-level), When Received (receipt-level)
- Configure at item level in Items form Production tab, overridable per BOM line in material detail
- Use manual issue for expensive, serialized, or lot-tracked components requiring traceability
- Set default backflush method in Master Data > Item Defaults to reduce per-item configuration effort
Operation-Level Backflush and Material Linkage
For operation-level backflushing (When Complete), SyteLine links each BOM material to a specific routing operation using the Operation Number field on the BOM material line. When that operation is reported complete, only the materials linked to that operation are issued from inventory. This linkage is critical for accurate WIP tracking—without it, SyteLine issues all materials at the first operation, which overstates WIP consumption early in the production process. Configure operation-material linkage in the BOM form by setting the Operation field on each material line to match the routing operation where the material is physically consumed. For materials consumed across multiple operations (e.g., lubricant used at every machining step), create separate BOM lines per operation with proportional quantities. The Backflush Quantity Basis setting determines whether backflush quantities are calculated from the job quantity (planned consumption) or the actual quantity reported at the operation (actual consumption adjusted for scrap). Use actual-based calculation for processes with variable scrap rates.
- Link BOM materials to specific routing operations using the Operation Number field on material lines
- Operation-complete reporting triggers backflush only for materials linked to that specific operation
- Split materials consumed across multiple operations into separate BOM lines with proportional quantities
- Configure Backflush Quantity Basis: planned (job quantity) or actual (reported quantity with scrap adjustment)
Exception Handling and Inventory Accuracy
Backflushing assumes that actual material consumption matches BOM quantities, which is rarely perfect. Scrap, substitutions, and yield variations create discrepancies between backflushed quantities and actual consumption. SyteLine provides several mechanisms to handle exceptions. The Backflush Variance Tolerance in Production Parameters defines the acceptable percentage deviation between expected and actual consumption—transactions exceeding this threshold are flagged for review in the Backflush Exceptions report. For scrap handling, configure the Scrap Percentage on BOM material lines to include expected scrap in backflush calculations. When actual scrap differs from expected, use the Material Adjustment transaction to correct the difference. Implement cycle counting on backflushed items at higher frequency (weekly or bi-weekly) than manually issued items, because backflush errors accumulate silently. The Backflush Reconciliation report compares backflushed quantities against physical counts to quantify cumulative backflush accuracy. Target 98%+ accuracy; below this threshold, the backflush configuration or BOM quantities need correction.
- Configure Backflush Variance Tolerance in Production Parameters to flag excessive consumption deviations
- Set Scrap Percentage on BOM material lines to include expected scrap in backflush quantity calculations
- Cycle count backflushed items weekly or bi-weekly since backflush errors accumulate without visibility
- Use Backflush Reconciliation report to measure cumulative accuracy—target 98%+ for reliable operations
Implementing backflushing in SyteLine? Our consultants configure backflush workflows that maintain inventory accuracy—schedule a consultation.
Related Resources
SyteLine Production Order Configuration Guide
Configure SyteLine production orders. Job order types, status workflows, numbering schemes, and manufacturing execution setup for CloudSuite Industrial.
Infor SyteLineSyteLine Shop Floor Control Module Configuration
Configure SyteLine Shop Floor Control. Transaction entry, operation reporting, WIP tracking, and production visibility for manufacturing execution.
Infor SyteLineSyteLine Labor Tracking and Reporting Configuration
Configure SyteLine labor tracking. Employee time reporting, labor rate setup, attendance integration, and efficiency analysis for manufacturing operations.