I am seeing an issue repeatedly with the costs of our Manufacturing Orders, but I am having trouble duplicating it intentionally. The issue is that upon completing the Manufacturing Order (using MO Receipt Entry), our Outsource costs are doubling.
When we set up a Manufacturing Order for an item that requires Outsourced Routing, we insert the cost per unit for the outsourced service in the Labor Time field. This cost per unit matches the cost per unit in the PO for the service, which we create using the MOP/POP link.
Looking at the Manufacturing Order Variance as I progress towards completion of the order, I can see that the cost from the Labor Time field gets applied to "Production Costs", and once the PO is received, that cost gets applied to "Costs Put Into WIP". It is the "Costs Put Into WIP" value that doubles when the Manufacturing Order Receipt is completed. I can tell if this Outsource cost doubling will occur before completing the MO Receipt by looking at the Labor/Machine Cost Entry screen. When the doubling occurs upon completion of the MO receipt, it appears to be because in addition to the Outsourced Costs Collected and Collected Costs Available, there is an additional value of the same amount in Outsourced Costs to Backflush.
This Costs to Backflush dollar amount is what is so confusing. I have not been able to determine a repeatable scenario that causes a Cost to Backflush to appear using our standard practice when setting up Manufacturing Orders, but we still keep having it somehow show up there, and consequently doubling our outsource costs.
I cannot find anywhere that we have marked such costs to be backflushed, and in fact the option to Auto-Backflush Labor costs is not selectable as an option in the Outsourced Routing Sequence.
Does anyone have any insight that may shed some light on a solution to this mysterious problem? We basically had to stop using Manufacturing Orders because it became such a problem, but we need to be able to do so and have the costs flow accurately and reliably. This doubling does not seem to occur every time, which is part of what makes it such a maddening issue to nail down, but it happens frequently enough to be highly disruptive.
