Practice Guide OPM

PRACTICE GUIDE Oracle Implementation Process Manufacturing

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Asad Soomro

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Note to Holders: IIL –Process Manufacturing Practice Guide

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If you receive an e lectronic copy of this document and print it out, please write your name on the equivalent of the cover page, for document control purposes. If you receive a hard copy of this document, please write your name on the front cover, for document control purposes.

IIL –Process Manufacturing Practice Guide

Contents

......................................... ............................ ............................ ............................ ............................ ............................ .................... ......ii Document Control ........................... ......................................... ............................ ............................ ............................ ............................ ............................ .................... ...... 5 About This Manual ........................... .......................................... ............................ ............................ ............................ ............................ ...................... ........ 6 Firm Planned Order (FPO)............................ .......................................... ............................ ............................ ............................ ........................ .......... 6 Firm Planned Order Creation ............................ ............................ .............. ............................ ............................ ............................ ...................... ........ 8 Convert Firm Planned Order into Batch ......................................... ............................ ............................ ............................ ............................ ............................ ............................ ......................... ........... 10 Batch ........................... ........................................ ............................ ............................ ............................ ............................ ............................ .................. .... 10 Batch Creation .......................... .......................................... ............................ ............................ ............................ ............................ ......................... ........... 11 Batch Transaction ............................ .......................................... ............................ ............................ ............................ ............................ ......................... ........... 12 Batch Completion ............................ .......................................... ............................ ............................ ............................ ............................ ............................ ............................ .................... ...... 13 Formula............................ ......................................... ............................ ............................ ............................ ............................ ........................... ............. 13 Formula Creation ........................... ......................................... ............................ ............................ ............................ ............................ ............................ ...................... ........ 16 Process Routing ........................... .......................................... ............................ ............................ ............................ ............................ ........................... ............. 16 Defining Routing ............................ .......................................... ............................ ............................ ............................ ............................ ............................ .................. .... 17 Routing Steps ............................ .......................................... ............................ ............................ ............................ ............................ ............................ ............................ ...................... ........ 18 Recipe ............................ .......................................... ............................ ............................ ............................ ............................ ............................ ................ 18 Recipe Creation ............................ .......................................... ............................ ............................ ............................ ............................ ...................... ........ 19 Recipe Validity Rule ............................


About This Manual

This Practice Guide is aimed towards enhancing a User’s understanding of Oracle Operation Process Manufacturing functionality. It describes the important processes involved in running Process Manufacturing. Manufacturing.


Firm Planned Order (FPO)

Firm Planned Order Creation

Responsibility: Responsibility: Production Supervisor. (N) Production supervisor >

Navigate to the Create a Document Form window

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Organization Name = Inventory (By Default).

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Document Type = Select Firm Planned Order

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Document Number = If you are using automatic document numbering, then a document number is assigned automatically and displays in this field after the Firm planned order is created and if you are using manual document numbering, then enter the number for the Firm planned order. When u save your work it will be automatically generate.

(T) Recipe.

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Recipe = Enter recipe name.

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Version = Enter version number if available.

(T) Product Output.

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Product = Required Product

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Product Quantity = Required quantity.

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UOM = Unit of measure required for the product

3. (T) Total Output

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Recipe = Already defined in Header field. fie ld.

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Version = Already defined in Header Field.

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Output Quantity = Required quantity

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UOM = Unit of measure of Required Product.

4. (T) Total Input IIL –Process Manufacturing Practice Guide

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Version = Already defined in Header field.

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Output Quantity = Required quantity

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UOM = Unit of measure of Required Product Recipe.

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Validity Rules by Cost = Select Validity rules by cost to view validity rules in the order of least cost.

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Planned Start = Enter Planned Start date for the Firm planned order. The current date and time is the default.

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Planned Completion = Enter Planned Completion date for the Firm planned order. This date is calculated automatically from the routing item lead time. If a routing exists, then the total routing time is added to the Planned Start date to calculate the Planned Completion Date. If a routing does not exist, then the fixed and variable lead times entered on the Item Master are added to the Planned Start date to calculate the Planned Completion date. Required Completion = Indicate the date and time required for Firm planned order completion. The Planned Completion date is the default.


Convert Firm Planned Order into Batch

Responsibility: Responsibility: Production Supervisor. (N) Production supervisor > Firm Planned Order Details

Put Document number and click to find > Planned order Details Window

Go to Menu > Tools > Convert firm planned order to Batch window will open

‐ Product = Displays the Product code and description for the primary product produced by the firm planned order

‐ Start = Enter start date ‐ Completion = Enter completion date ‐ Quantity per Batch = Enter the quantity of product to produce by each batch created from firm planned order.

‐ Product Quantity = Displays the quantity of product to produce by the batch. ‐ Batches = Enter the total number of batches to produce from firm planned order.

‐ Assigned = This field is display only and displays a quantity that is equal to the quantity per batch multiplied by the number of batches.

‐ Unassigned = this field is also display only and displays the difference between the product quantity and assigned quantity.

‐ Offset Type = Enter the offset type as the multiple batch scheduling method to use by selecting ; •

•

Start to Start if the Firm Planned Order requires scheduling of several batches that can start one after the other, their start dates separated only by any offset that is specified in the Batch Offset field, or start simultaneously if you enter a zero offset. Finish to Start if the Firm Planned Order requires scheduling of several batches that can only start after each individual batch has finished. Finish to Start is required when multiple batches are scheduled.

‐ Batch Offset = The amount of time between batches. IIL –Process Manufacturing Practice Guide

‐ Lead Time = Enter the number of hours required to manufacture one batch. The following fields are display only

‐ Seq = Enter the sequential number of each batch ‐ Batch Num = Batch document number. ‐ Batch Quantity = Displays the quantity of product to produce by the batch. ‐ Planned Start = Displays the planned start date and time for the batch. ‐ Planned Completion = Displays the completion time for the batch. Click on Ok to convert.


Batch Batch Creation Responsibility: Responsibility: Production Supervisor. (N) Production supervisor >

Navigate to the Create a Document Form window

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Organization Name = Inventory (By Default).

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Document Type = Batch (If u create batch then select Batch).

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Document Number = If you are using automatic document numbering, then a document number is assigned automatically and displays in this field after the batch is created and if you are using manual document numbering, then enter the number for the batch .When u save your work it will be automatically generate.

(T) Recipe.

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Recipe = Enters recipe name.

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Version = Enters version number if available.

(T) Product Output.

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Product = Required Product

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Product Quantity = Required quantity.

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UOM = Unit of measure required

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(T) Total Output

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Output Quantity = Required quantity.

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UOM = Unit of measure required for the product.

(T) Total Input

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Output Quantity = Required Product.

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UOM = Unit of measure required.


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Validity Rules by Cost = Select Validity rules by cost to view validity rules in the order of least cost.

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Planned Start = Enter Planned Start date for the batch. The current date and time is the default.

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Planned Completion = Enter Planned Completion date for the batch. This date is calculated automatically from the routing item lead time. If a routing exists, then the total routing time is added to the Planned Start date to calculate the Planned Completion Date. If a routing does not exist, then the fixed and variable lead times entered on the Item Master are added to the Planned Start date to calculate the Planned Completion date. Required Completion = indicate the date and time required for batch completion. The Planned Completion date is the default.

Batch Transaction

Responsibility: Responsibility: Production Supervisor Responsibility. (N) Production supervisor > Batch Details

Find Batches (INV)

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Document = Query the Batch Document to release.

Batch Details (INV)

All the input information is display in the Batch Details form when creating a batch.

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Steps = Click on steps.

Batch Steps (INV)

Go to Menu>Actions>Release and click on OK.


we

Material Exceptions (INV)

Material Exceptions window shows Ingredient Target Qty and transacted Qty also. Tick on transact and click on Select Available Inventory. Put transact quantity and done. Select Proceed for transfer step into WIP.

Batch Completion

Responsibility: Responsibility: Production Supervisor Responsibility. (N) Production supervisor > Batch Details Find Batches (INV)

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Document = Query the Batch Document to Complete Production

Batch Details (INV)

All the input information is display in i n the Batch Details form when we creating a batch and also in Batch shows WIP status.

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Steps = Click on steps.

Batch Steps (INV)

Go to Menu>Actions>Complete and click on OK. Material Exceptions (INV)

Material Exceptions window shows Product Target Qty and transacted Qty also. Tick on transact and set sub‐inventory, locator and lot number. (If set automatic then number automatically generates). Put transact quantity and done. Select Proceed for step Completion. After completion of Batch close the batch, for this Go to Batch Details Window>Menu>Actions>close Window>Menu>Actions >close and click on OK.


Formula Formula Creation

Responsibility: Responsibility: Formulator. Formulator. (N)Formulator (N)Formulator > Formulas

Navigate to the Formula Details Windows;

‐ Formula = This is a code assigned to the formula ‐ Version = Enter Version of the formula ‐ Description = Enter Brief explanation of a formula ‐ Comments = Enter Remarks or notes enter for the formula ‐ Class = Enter a Class for the formula to identify how it is categorized. ‐ Organization =Displays the name of the organization responsible for the formula.

‐ Organization Description = Description of Organization of formula.

(T) Products

‐ Product = Enter the product code for each item produced by this formula. ‐ Revision = Enter the revision or leave blank blank if there is no revision ‐ Description = Enter Description of the product or defaults from item master table

‐ Quantity = Enter quantity of the product that this formula yields. ‐ Scale type = Fixed if the product is not scalable and proportional if the product is scalable.

‐ Yield Type = Select yield type automatic when products are yielded automatically when the batch is completed, Manual when products are yielded manually and Automatic by step when products yielded automatically as the step is completed.

‐ Cost Allocation = indicates how the cost of this item is allocated for financial rollup purposes. IIL –Process Manufacturing Practice Guide

(T) By ‐Products

‐ By‐products = By‐Product code for byproduct items produced by this formula. Byproducts are not required for a formula.

‐ Description = The description of the By‐product entered displays. This defaults from the item master table.

‐ Quantity = Quantity of the byproduct that this formula yields. The quantity entered in this field is the default standard quantity used for the recipe. It can be changed at the recipe level. Required if you enter one or more byproducts for the formula.

‐ Scale type = Fixed if the product is not scalable and proportional if the product is scalable.

‐ Yield Type = Select yield type automatic when By‐products are yielded automatically when the batch is completed, Manual when products are yielded manually and Automatic by step when products yielded automatically as the step is completed.

‐ By‐Product Type = Enter the following By‐Product type: Re‐Work if the material generated requires rework. Sample if the material generated is used as a sample for quality inspection. Waste if the material is a waste product. Yield if the byproduct is material that is yielded for use in another process.

(T) Ingredients;

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Ingredient = Enter the Ingredient code for each item required by this formula. A minimum of one ingredient is required for a formula.

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Revision = Enters the revision, or leave this field blank.

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Description = This defaults from the Item Master table.

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Quantity = Enter Quantity of the product that this formula yields.

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UOM = The inventory unit of measure for the item is the default.

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Scale Type =


• • •

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Fixed if the ingredient is not scalable, Proportional if the ingredient is scalable and Integer if the ingredient is scalable by multiples.

Scale Multiple = Enter the Scale Multiple as the scaling increment for the ingredient. Consumption Type = Select the Consumption Type to indicate the type of ingredient consumption as: • Automatic when ingredients are consumed automatically when the batch is completed. • Manual when ingredients are consumed manually. • Incremental when ingredient consumption is calculated by i ncremental back flushing. • When ingredients are consumed automatically as the step is completed.

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Contribute To Yield = Select Contribute to Yield as Yes or No to indicate whether the material contributes to the yield.

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Contribute to Step Quantity = Select Contribute to Step Quantity as Yes or No to indicate whether the material contributes to the to the step quantity.

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Required Qty = Displays the result of multiplying the formula quantity by the quantity one plus the scrap factor expressed as a percent.

Save the window


Process Routing Defining Routing

Responsibility: Responsibility: Process Engineer. (N)Process Routing >

Navigate to the Process Routing Details window. Note: Enter the Context organization if it is requested.

‐ Routing = Enter the code for Routing. ‐ Routing Version = Enter the version for the routing. ‐ Status = Default status New and change status after entering all relevant information.

‐ Routing Description = Briefly describes the routing. ‐

Class = Enter the class for the routing to identify how it is categorized.

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Class Description = By default the class the description taken.

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Valid From = Enter the valid from date for the routing. The default date is the current system date.

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Valid To = Enter a Valid to date for the expiration of this routing. If there is no expiration date for this routing, then leave the field blank.

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Quantity = This is the total quantity of material for the routing, and is used to scale individual step requirements. requirements.

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UOM = Enter the process quantity unit of measure associated with this routing.

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Planned Loss = Enter the value of planned loss. This value is expressed as a percent.


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Theoretical Loss = Enter theoretical loss value, this value is i s entered on the theoretical process loss window, and is based on the value assigned to the class associated with this routing.

Enforce Step Dependencies = This indicate the recipe using this routing enforces step dependencies. When you select this indicator, routing steps must be released and completed manually.

Routing Steps

‐ Step = Enter the step number to associate with an operation in this routing. ‐ Operation = Enter the code for the operation performed in this operation. ‐ Version = Enter a version number for the routing. ‐ Description = set as default. ‐ Step Quantity = Enter the operation step quantity as the quantity of material associated with this step.

‐ UOM = it displays for the step quantity unit of measure. ‐ Release Type = Select release type as , •

•

Automatic if the step is automatically released or completed when subsequent steps are released or completed, Manual if the step must be released and completed manually. Save the window.

‐ Click on Step Dependencies to display the routing step dependencies window. ‐ Click on Edit operation to display the Process operation details activities window.

‐ Click on Edit step line to display Routing step line window.


Recipe Recipe Creation Responsibility: Responsibility: Formulator. Formulator. (N)Formulator (N)Formulator > Recipe

Navigate to the Recipe Details window;

‐ Recipe = Recipe is a recipe code which we use for manufacturing a specified product, for other products the recipe is different.

‐ Version = Version of Recipe ‐ Status = The current status of the recipe ‐ Description = Explanation of the recipe. ‐ Product = This is a code for the primary product produced by the recipe. ‐ Quantity = Product quantity, which will produce by the recipe. ‐ UOM = Unit of measure required for the product ‐ Formula = Formulas that defines the products, ingredients, and byproducts. ‐ Version = version of the formula for the recipe. ‐ Creation Organization = Formula Owner Organization. ‐ Routing = Plant Name. ‐ Version = Routing Version ‐ Owner Organization = It is the default organization for the owner of the recipe. ‐ Planned Loss = Enter the Planned Loss as the loss of process material observed during production of a batch using the recipe. If a value is not entered in this field, then it defaults to the value entered for Theoretical Process Loss.

‐ Theoretical Loss = the hypothetical loss of process material associated to a routing as a percentage. If a routing is not associated to a recipe, or if a routing class is not associated to a given routing, and process loss is not defined for that routing, this field is blank. IIL –Process Manufacturing Practice Guide

‐ Total Output Qty = Calculate Total output qty displays with its UOM 1. (T) Plant/Laboratory. Plant/Laboratory.

‐ Organization = Enters Organization code that the process loss is being defined ‐ Organization Name = Enters description of the plant or laboratory ‐ Type = Indicates whether this is a plant or a laboratory. ‐ Process Loss = Enters the material percentage that is loss through process. This field is blank if you did not enter a routing 2.

(T) Customer.

‐ Customer = Enter the Customer Number ‐ Name = Indicates the name of the customer associated with the customer number entered.

‐ Operating Unit = The parent organization associated to the customer entered. ‐ Ship to Locator = Customer Postal Address 3. (T) Step Quantity. I f a routing is not entered, then this region is not available.

‐ Step = This indicates the step number associated with the listed operation in the routing.

‐ Operation = Displays the operation associated with the step. ‐ Charges = This shows the total calculated charges for the step. Verify all the parameters and save the recipe.

Recipe Validity Rule Click on Validity Rules Button > Recipe validity rules details Go to Menu>Actions>Change Menu>Actions>Change status Save


Practice Guide OPM

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