Overview of Work in Process

Overview of Work in ProcessOverview

Overview of Work in ProcessSystem References

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Overview of Work In Process

Instructor NoteAll practices in this course have been tested in the Manufacturing, Vision Operations (USA) instance, using the M1 and M3 organizations.Some of the practices in this course are built to lead the student through a process, not to enter any data, but rather to show the student how the Work in Process is used and implemented.The practices assume that Inventory Account Aliases are set up in the Manufacturing, Vision Operations (USA) database. If not, you may want to set them up in Inventory > Setup > Account Aliases for ease of use in enter account information for WIP accounting classes and resources.Objectives

Topics Covered in this Course

Agenda

Introduction to Oracle Work in Process

Introduction to Oracle Work in Process

Oracle Work in Process supports the following areas in manufacturing processes. Inquiries and reports give you a complete picture of transactions, materials, resources, costs, and job and scheduling progress on your shop floor.

Manufacturing

Different manufacturing methods are supported, or a combination of methods, including the following types of jobs: discrete, project, repetitive, flow, lot based, assemble-to-order, and configure-to-order.

Production Scheduling

Various scheduling modes are supported including forward, backward, manual, and midpoint. You can schedule using fixed, variable, and overlap time element.

Material Control Issue and return components from inventory

Backflush components automatically using operation or assembly completion

Replenishmaterial using rules based picking

Supports serial number, lot-controlled, and revision controlled components and assemblies

Supports outside processing suppliers

Introduction to Oracle Work in Process

Introduction to Oracle Work in Process (continued)

Shop Floor Control Move and complete assemblies between and within operations

Charge resources and overheads automatically

Usestandard and alternate routings and revisions

Resource Tracking Define and control resources (people and machines)

Charge resources based upon their charge type

Manual and automatic resource transactions

Cost Transactions Charge labor, machine, and outside resources automatically or manually

Cost discrete jobs using standard or weighted average costs

Mobile Supply Chain ManufacturingIf you have Mobile Supply Chain Applications installed, you can perform work in process transactions including issuing and returning material, moving, completing, and scrapping assemblies using a mobile client device interfaced with a networked computer system.

Lean Manufacturing

Lean Manufacturing

Lean manufacturings goal is to eliminate waste. Waste is defined as anything that does not add value to the product or service. In the 1940s, Taichii Ohno and Shigeo Shingo of the Toyota Company named seven wastes commonly found in physical production:

Over-Productionproducing more than the customer needs or too early,caused by incorrect forecasting

Large Inventoriesparts you are not using, paid for, and are taking up storage space

Defectsunusable product that does not meet customer specifications

Unnecessary Transportationfor materials between processes

Waitingany delays in the process

Unnecessary movementby employees such as looking for parts, tools, prints, or help

Over-Processingmore work than is necessary to perform transactions, often due to poor design

Agenda

Manufacturing Methods

Discrete Manufacturing Jobs

Discrete Manufacturing Jobs

A number of features are available for discrete jobs including:

Creating both standard and non-standard jobs

Assigning bills and routings to create material requirements, schedule operations, and resource requirements

Alternate bills of material

Attachments of illustrative or explanatory files

Standard discrete jobs control the material, resources, and operations required to build an assembly; and also collect manufacturing costs.

Non-standard discrete jobs control material and resources, and collect costs for miscellaneous manufacturing activities such as repair work.

Instructor NoteRefer participants to the Oracle Work in Process Users Guide for detailed information regarding setup and implementation prerequisites for discrete jobs.Project Manufacturing Jobs

Project Manufacturing JobsIf you have Oracle Project Manufacturing installed, you can use project jobs with the ability to track the material and manufacturing costs specific to a given project. You can issue project or common inventory to project jobs, and charge resources and overhead. You can add project/task references to both standard and non-standard discrete jobs.

Instructor NoteRefer the participants to the Oracle Project Manufacturing Users Guide, and Oracle Project Manufacturing Implementation Guide for detailed information regarding the setup and implementation prerequisites, and requirements for project jobs.Repetitive Manufacturing Schedules

Repetitive ManufacturingRepetitive schedules enable you to control your repetitive production quantities and charge all production costs to the assembly itselfeliminating the need for individual discrete jobs.

You can define any number of line and assembly associations, which establishes a link between an assembly and the production line that the assembly is manufactured on.

Instructor NoteRefer participants to the Oracle Work in Process Users Guide for detailed information regarding setup and implementation prerequisites for repetitive schedules.Flow Manufacturing Schedules

Flow Manufacturing

If you have Oracle Flow Manufacturing installed, you can use production lines and rate-based schedules instead of work orders to control production. Production occurs on flow lines that have been designed and balanced to synchronize your activities to a continuous flow.

Flow Manufacturing utilizes Lean principles. The focus of Lean production and Flow Manufacturing is to provide products in the shortest possible time, at the lowest possible cost, and in the highest possible quality.

Instructor NoteRefer the participants to the Oracle Flow Manufacturing Users Guide for detailed information regarding the setup and implementation prerequisites, and requirements for flow schedules.Shop Floor Manufacturing Lot Based Jobs

Shop Floor Manufacturing Lot Based Jobs

If you have Oracle Shop Floor Management installed, network routings are used to comprise all possible operations defined for manufacturing a particular assembly. While discrete jobs use standard routings, lot based jobs use network routings.

The primary feature of network routings is to define different paths for the next operation. There is a unique start and last operation defined in the network. When this information is defined, a network of operations is available for processing a lot based job on the shop floor.

Instructor NoteRefer the participants to the Oracle Shop Floor Manufacturing Users Guide for detailed information regarding the setup and implementation prerequisites, and requirements for lot based jobs.Configure To Order (CTO) Manufacturing

Configure To Order (CTO) Manufacturing

A configure to order environment is one where the product or service is assembled on receipt of the sales order. Oracle Applications supports the configure to order environment with a range of features in order entry, demand forecasting, master scheduling, production, shipping, and financial accounting. You can have Pick-to-Order (PTO), Assemble-to-Order, and final assembly orders.

Instructor NoteRefer the participants to the Oracle Configure To Order Process Guide for detailed information regarding the setup and implementation prerequisites, and requirements.Assemble To Order and Final Assembly Orders

Assemble To Order (ATO) and Final Assembly OrdersYou can manually or automatically define jobs to build custom configurations for assemble to order products. An assemble to order model consists of a model bill of material, with optional items and option selection rulesand a configuration manufactured from mandatory components and selected options.

There are three types of ATO items:

AutoCreated Configuration Items: Configuration items created by CTO for a sales order placed for a model and options

Preconfigured Items: An item defined for a base model and a configured bill of material

Standard ATO Items

You can create final assembly orders for ATO items automatically. These discrete job orders are created per a single job for single sales order delivery. You may also associate sales orders to discrete jobs for any item, thereby allocating production to specific customers.

Instructor NoteRefer the participants to the Oracle Configure To Order Process Guide for detailed information regarding the setup and implementation prerequisites, and requirements.Agenda

Overview of Creating Discrete Jobs

Overview of Creating Discrete Jobs

You can create both standard and non-standard discrete jobs.

Standard jobs control the material, resources, and operations required to buildan assembly and collect its manufacturing cost.

Non-standard jobs control material and collect costs for miscellaneousmanufacturing activity.

Routings are used to schedule job production activities and create requirements. If you have Oracle Shop Floor Management installed, you can use lot based jobs which follow a network routing. Network routings provide flexibility in determining the series of operation moves for the job.

You can build jobs for assemblies for both lot and serial control. You can track your jobs using serial control throughout the manufacturing process. This enables you to assign, perform serial transaction entry, import serial numbers, and print serial number labels. This functionality is supported through Oracle Mobile Supply Chain Applications.

Oracle Work in Process offers two single interfaces in for discrete manufacturing:the Discrete Execution Workstation or the Manufacturing Execution System (MES) Workstation.

Overview of Creating Discrete Jobs

Discrete Workstation and MES WorkstationThe Discrete Workstation provides a single interface to perform multiple shop floor functions, without navigating to a number of transaction windows. It displays information by department or resource, and it lists all of the job operations for immediate and future dispatch. You can perform transactions directly on the workstation's tabs, or navigate to the corresponding Work in Process windows.

Oracle Supply Chain Management Applications Release 12 offers the Manufacturing Execution System providing three functional modes including Administrator, Supervisor, and Operator. The MES Workstation for the operator provides a single interface to perform multiple shop floor functions, without navigating to a number of transaction windows. Shop floor operators can view the jobs assigned to specific work centers, view requirements and instructions for performing work. The Manufacturing Execution System can be configured for actions, display, security, and transactions for the operator and supervisor roles. You can personalize application pages without modifying underlying code.

Discrete Life Cycle

Discrete Life CycleThe discrete life cycle consists of:

Defining a job. The job can be one of the various manufacturing types supported by Oracle Work in Process including standard and non-standard discrete jobs, project, repetitive, flow, lot based, assemble-to-order, and configure-to-order.

Building the job by assigning bills, routings, operations, material, and resources.

Updating the job as you move on the shop floor and create transactions.

Closing the job when the work is completed.

Agenda

Overview of Material Control

Overview of Material Control

By synchronizing your bill of material with routings, you can specify when and where materials are to be issued or backflushed to your jobs and schedules. Supply Types control whether the material is issued or backflushed to the job or schedule; and controls how the material is costed to the job or schedule.

Overview of Material Control

Overview of Material ControlIssue and Return Material

Material can be issued from inventory, and you can return components issued to jobs and schedules back to inventory.

Backflush Material

These are material transactions that automatically issue component items into work in process from inventory when you move or complete the assembly.

Replenish Material

You can replenish supply subinventories and locators to ensure that materials are available for backflush transactions,

Agenda

Overview of Resource Management

Overview of Resource Management

You can define and control resources during your production process using these features:

Resource TypesResources are charged based upon their charge type such as: WIP Move, Manual, PO Move, and PO Receipt.

Resource RequirementsResources can be added to existing routing operations and operations not on the original routing.

Manual and Automatic Resource TransactionsYou can manually charge resources associated with operations. When you move job and schedule assemblies forward in their routing, pre-assigned WIP Move resources are automatically charged at their standard rate.

Outside Processing ResourcesYou can assign outside processing resources to job and schedule routing operations.

Automatic Overhead ChargingThe appropriate overhead costs are automatically charged as you move assemblies through the shop floor.

Overview of Resource Management

Overview of Resource Management (continued)

Resource Reporting

You can report on resource transactions, efficiencies, and costs by job, schedule, department, or resource to get a complete history of resource activities.

Resource WorkbenchThe Resource Workbench displays selected resources and corresponding departments display in a tree hierarchy. You can view job and operation schedules, and resource load compared to capacity through two graphical displays: the Job Workbench and the Resource Workbench. You can interactively reschedule jobs, operations, and resources.

Agenda

Overview of Production Scheduling

Overview of Production Scheduling

Scheduling establishes expected dates and times for material and resource requirements. It also establishes expected dates and time for the assemblies built.

Oracle Work in Process uses two scheduling modes:

Infinitethe infinite scheduling engine assumes infinite capacity

Constraint-based provided by two constraint-based applicationsManufacturing Scheduling and Production Scheduling

If you have Oracle Manufacturing Scheduling installed, you can enable the constraint-based scheduler which considers resource and material constraints. All scheduling is based on the calendars, shifts, departments, resources, routing, and planning you define in Oracle Bills of Material - and jobs and production lines defined in Work in Process.

Production Scheduling in Oracle Planning uses sophisticated scheduling algorithms.

Overview of Production Scheduling

Overview of Production Scheduling (continued)

Detailed Scheduling

Oracle uses detailed scheduling to schedule discrete production. Detailed scheduling applies resource usage defined by routings and resource availability.

Job Workbench

The Job Workbench enables you to view and reschedule jobs and operations, providing a visual job oriented display of work on the shop floor. You can interactively reschedule jobs, operations, and resources. You can manually control the rescheduling or let the system automatically schedule.

Agenda

Overview of Shop Floor Control

Overview of Shop Floor Control

Agenda

Overview of Work In Process Costing

Overview of Work In Process Costing

Agenda

Summary

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Overview of Work in Process

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