When production runs smoothly, consumption tracking often fades into the background. But when your actual usage doesn’t match what Business Central says it should, suddenly “flushing” becomes one of the most important topics on the shop floor.
Flushing—how Business Central records material consumption—affects everything: inventory accuracy, costing, WIP accounting, and even scheduling. The method you choose shapes how and when items are consumed from inventory. Get it wrong, and you’re chasing variances. Get it right, and you’re closing orders faster with cleaner data.
What are the different flushing methods in Business Central?
Forward flushing records material consumption at the start of an operation or production order. It’s great when you can predict exactly what will be used.
Backward flushing posts consumption automatically at completion. It’s simpler and faster for operators but assumes usage matches the BOM exactly.
Manual flushing is preferred when control matters most. You record consumption when you know it’s accurate—after inspection, quality checks, or when lots and serials are confirmed.
Business Central also supports pick + manual flushing without requiring a warehouse pick document.
How do routing link codes improve flushing accuracy?
Routing link codes enable you to associate each BOM component with a specific routing operation. If you’re using flush by operation, consumption posts as each operation finishes. This improves reporting accuracy and aligns with tools like Shop Floor Insight, where operators record progress in real time.
What should I watch for when using flushing with tracked items?
Flushing tracked lots isn’t automatic during backward flushing. You’ll need manual intervention for lot or serial tracking. Component substitutions also don’t automatically update your flushing logic.
Many manufacturers rely on Enhanced Planning Pack or Shop Floor Insight to ensure substitutions or scrap adjustments flow correctly into production and costing.
How does flushing affect inventory valuation and WIP?
Forward flushing moves cost out of inventory earlier, while backward flushing delays consumption until completion. Understanding these timing differences is critical for accurate reporting.
Aligning flushing points with operation timing helps balance production efficiency with financial accuracy—especially when using Shop Floor Insight or MxAPS.
Can I mix different flushing methods?
Yes. Mixing manual and backward flushing in the same BOM is valid. Fasteners or low-cost materials may flush automatically, while expensive or critical components require manual verification.
The goal is not uniformity—it’s alignment with your plant’s actual operations.
Where do I define and troubleshoot flushing?
You can define flushing methods on the Item Card—Forward, Backward, Manual, or Pick + Manual. Overrides are also possible per component directly on a production order line.
Common errors include:
- Missing routing link codes
- Items set to backward flush, but operations not reported as finished
- Components on manual flush with no consumption entry posted
Audit item settings periodically to avoid hidden variances.
One post I found helpful dives deep into the topic and outlines practical options.
🛈 This post is based on publicly available information and user scenarios related to Business Central.
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