Auto Backflushing System
Automating production reporting and SAP backflushing with accurate data, while intelligently handling bad or inconsistent production inputs.
Duration
5 months
tEAM SIZE
4 Engineers & 1 SAP Specialist
monitoring coverage
OPERATIONAL Scope
Real-time
Production Facilities
The Challenge
A large FMCG production network faced inefficiencies in backflushing production data into SAP due to:
Manual generation of production reports
Inconsistent or corrupted production data
Delays in recording actual production outputs
Errors in inventory and cost reporting
Lack of real-time visibility for production managers
“Without automated backflushing, production data integrity depended on error-prone manual processes, causing delays and inaccurate reporting.”
I
Manual Backflushing & Bad Data in SAP
Our Solution
Enterprise Auto Backflushing Platform
We designed a system that automatically collects production reports, validates and cleanses the data, and pushes accurate backflushing information into SAP. The platform integrates with existing shop floor systems, ensuring minimal manual intervention while maintaining data integrity.
System Architect
Data Capture Layer
Data Validation & Cleansing Engine
Pull production data from machines, MES, and ERP logs
Detects missing, inconsistent, or corrupted entries; applies correction rules
SAP Integration Layer
Automated backflushing and inventory updates in SAP
Dashboard and Analytics Layer
Real-time production reporting, error tracking, and audit logs
Results and Impact
Automating production reporting and SAP backflushing eliminated manual errors and delays, ensuring accurate data across all production lines. Production managers gained real-time insights into output, while audit and compliance teams now have complete traceability of data corrections.
The system ensures consistent inventory updates, correct costing, and streamlined reporting — creating a scalable framework for production automation and SAP integration excellence.
