Company Type
Albright & Wilson, a specialty phosphorus chemicals manufacturer; transformation of two food-grade phosphorus plants (wet and dry processes, US and Canada) under cGMP/CFR Title 21. The hyper-backflush concept originated here.
What Drove the Need
Multi-stage shifting/screening of bulk product processed directly from rail cars generated work orders and material consumption faster than anyone could key them
cGMP lot tracking of grades, dates, and shelf life had to be automatic
Business Impact
Production reporting from 3–5 days to real time; month-end close from 3+ weeks to under 1 day (Case 15)
Systems/Data Integration
Integrated with JDE World work orders, inventory, and manufacturing accounting; laboratory test results drive processing
Design
Work-order creation driven by lab results: multi-stage bulk processing auto-generates the bulk work order and backflushes both material lists
Lot control integrated with DSI barcoding; finished-good lots tracked on specific rail cars
Technology Stack
RPG on AS/400-DB2
DSI barcoding software
JDE World A7.3 (Manufacturing, Inventory with Lot Control, Product Costing, Manufacturing Accounting)
WO/Routing “Hyper-Backflush” Application
Automatically creates batch work orders for lot-controlled bulk chemical from the final output of lot-controlled finished goods; backflushes all bulk and consumed materials for both the auto-created bulk work order and the finished-good work order; tracks finished-good lots to specific rail cars.
