osfm and a manufacturing execution system: compatible partners
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OSFM and a Manufacturing Execution System: Compatible Partners. Training Day January 17, 2007. Objectives. Outline the mechanics of PI’s interface project Communicate the challenges encountered Discuss the solution components employed Share some tips and pitfalls. Agenda. - PowerPoint PPT PresentationTRANSCRIPT
OAC
OSFM and aManufacturing Execution System:
Compatible Partners
Training DayJanuary 17, 2007
Date: January 17, 2007Slide: Slide: 22NorCal OAUG Training DayNorCal OAUG Training Day
Objectives
Outline the mechanics of PI’s interface project Communicate the challenges encountered Discuss the solution components employed Share some tips and pitfalls
Date: January 17, 2007Slide: Slide: 33NorCal OAUG Training DayNorCal OAUG Training Day
Agenda
Introduction - Power Integrations Background on the Project Overview of PI Supply Chain Overview of OSFM Integration Challenges and Considerations Interface Components Lessons Learned Questions and Answers
Date: January 17, 2007Slide: Slide: 44NorCal OAUG Training DayNorCal OAUG Training Day
Power Integrations
Innovation in Power Conversion Fabless Semiconductor Manufacturer Headquartered in San Jose Founded in 1988 Leading supplier of high-voltage analog integrated circuits
(ICs) used in power conversion.– Enable compact, lightweight power supplies that are simpler to
design and manufacture, more reliable, and more energy-efficient than those made with competing technologies.
– Power a vast range of consumer and industrial electronics—computers, DVD players, TV set-top boxes, cell phone chargers, home appliances, telecom networking equipment, and many others.
Date: January 17, 2007Slide: Slide: 55NorCal OAUG Training DayNorCal OAUG Training Day
Project Background – Business Considerations
Issues: Camstar MESA used for tracking production only WIP/Inv Cost – done on massive spreadsheets Extraordinarily long and painful month end close
Solution: Implement OSFM & Inventory to manage WIP
valuation– In process Sort, Assembly, Test, Tape & Reel, etc– Wafer Bank, Die Bank, Untested, etc
Date: January 17, 2007Slide: Slide: 66NorCal OAUG Training DayNorCal OAUG Training Day
Replace Spreadsheet CostAccounting with OSFM
Install interface engine,develop and test interfaces
Project Background - Timetable
2006 2007
Upgrade to 11.5.10from 11.0.3
• Order Management• Inventory• Purchasing• Financials (GL/AP/AR/CM/FA)• Human Resources
Develop interfaceengine (eFabless)
• Receiving• Inventory• OSFM
Date: January 17, 2007Slide: Slide: 77NorCal OAUG Training DayNorCal OAUG Training Day
Overview – Supply Chain
DIEBANK
UNTESTED
WFRBANK
WFRBANK ASSY UN
TESTED
SORT DIEBANK
FG
TEST
Wafer Dlvd from Fab
SAN JOSE
OFFSHORESUBCONTRACTORS
TEST + LF
UNBAKED
BAKE + BAG
BAKE + T&R
HONG KONGDISTRIBUTION
TEST (& VA) FG FG
Date: January 17, 2007Slide: Slide: 88NorCal OAUG Training DayNorCal OAUG Training Day
OSFM Integration
Assets @ Standard Cost
I nventoryI tems,UOM,
QOH
Shop Floor Management
Lot- based J obs
Cost Management
PurchasingBills of Material
Cost Rolls
OSPRequisitions
Wafer POsOSP Blanket OrdersOSP Blanket Releases
WaferReceipts
GeneralLedger
WaferDieUntestedUnbakedFinished Goods
BOMsRoutings
DepartmentsResources
Expected YieldsAbsorption Rates
OSPReceipts
Assets(WI P Value)
Variances
Variances (PPV)
Standard Costs
MESA
Mesa-toOSFM
I nterf ace
Date: January 17, 2007Slide: Slide: 99NorCal OAUG Training DayNorCal OAUG Training Day
Challenges and Considerations
MESA uses single item number for multiple operations:– Wafer number for Wafer Bank, Sort, and Die Bank– FG number for Assembly, Test, and Finished Goods
Multiple Organizations with changes in inventory asset ownership
Not every transaction in MESA is necessary for Cost Accounting
Must avoid prematurely processing a “downstream” transaction for a given lot before “upstream” transaction is successfully played
Date: January 17, 2007Slide: Slide: 1010NorCal OAUG Training DayNorCal OAUG Training Day
Components – Getting Started - Tables
The necessary tables for each transaction were identifie
d
Date: January 17, 2007Slide: Slide: 1111NorCal OAUG Training DayNorCal OAUG Training Day
Components – Getting Started - Columns
•Every required column for each table was planned.
•eFabless rules were created for each (see Appendix for examples)
Date: January 17, 2007Slide: Slide: 1212NorCal OAUG Training DayNorCal OAUG Training Day
Components – Simplified OverviewAS400 eFabless Engine Oracle
MESA Transactions
Get Data from MESA Selected
Transactions
Write Data to Oracle
Read Results from Oracle
Rules and Lookups
Metered by Lot & Control Number
Success or Failure
ReceivingOSFM
Inventory
Date: January 17, 2007Slide: Slide: 1313NorCal OAUG Training DayNorCal OAUG Training Day
Components – Example of Transactions
4Job StartMode 2
UM = DIE
SORTDIE BANK
UM = DIE
YIELD %
LBR+OH
WAFERBANK
UM = WFR
7Lot Move
andCompletn
MESA
Wafer Dlvd from Fab
STRT
1P.O. Rcpt / Deliver
2000WAFERRECVG
MOVE2100
WAFERACCPT
16InterorgTransfer
WAFERBANK
UM = WFR
2200QC
2300WAFER
QUEMOVE
2400WAFERSORT
MOVE, SPLIT, CONV NOT INTERFACED to OSFM
Physicallyarrives in San Jose
MOVE,NOTINTFCD to OSFM
OR
AC
LEO
FFS
HO
RE
OR
GA
NIZ
ATI
ON
2450WS
STAGE
2900DIE
BANK
2475QC
STAGE
2500WSQC
MOVE
OR
AC
LES
AN
JO
SE
OR
GA
NIZ
ATI
ON
Date: January 17, 2007Slide: Slide: 1414NorCal OAUG Training DayNorCal OAUG Training Day
Components – Example of Transactions
7Lot Move
andCompletn
4Job StartMode 2
UM = EA
ASSEMBLY
YIELD %
DIE BANK
UM = DIE
OSPReqOSP
Blanket PO
OSPRelease
Receipt / Deliver OSP
OSPStd’s
UNTESTED
UM = EA
2900DIE
BANKMESA
2950DIE
STAGE
MOVE,SHIP NOTINTFCD to OSFM
16InterorgTransfer
DIE BANK
UM = DIE
Ownership retained in the
U.S. until receipt offshore
17P.O. Rcpt /
Deliver
3000ASSY
(POWR)
3000ASSY(PIC2)
16InterorgTransfer
UNTESTED
UM = EA
Ownership transferred at time of shipment to the
U.S.
INTRNST
RECV, MOVE NOTINTFCD to OSFM
3500ASSYRECV
4000UN
TESTDSHIPIN
TRNST RECV
Qty = Outs
OR
AC
LEO
FFS
HO
RE
OR
GA
NIZ
ATI
ON
OR
AC
LES
AN
JO
SE
OR
G
Date: January 17, 2007Slide: Slide: 1515NorCal OAUG Training DayNorCal OAUG Training Day
Lessons Learned
API user guides are not always clearfor example…– Initially used rcv_lots_interface for Receiving Deliver– Learned via TAR should be mtl_transaction_lots_interface
TRM Column descriptions are not always clearfor example…– Column Name = PRODUCT_CODE – TRM description = Stores the product name to identify the
source transaction for the record– Mandatory = No– Discovered it is required for Receiving Delivery (RCV)
Date: January 17, 2007Slide: Slide: 1616NorCal OAUG Training DayNorCal OAUG Training Day
Lessons Learned
Error messages are not always accuratefor example…– RCV_TP_ACCT_PERIOD_CLOSED error caused by
values unrelated to accounting periods.– Transactions set to ERROR status with no error message
Mapping the right rules and data values took longer than expected.
Need to be on the latest patchset Recognize the need to properly staff for on-going
monitoring of the transactions
Date: January 17, 2007Slide: Slide: 1717NorCal OAUG Training DayNorCal OAUG Training Day
Questions and Answers
Presenter Contact Information
Clark Stockard(408) 414-8879
Travis Cox(925) 786-1230
Date: January 17, 2007Slide: Slide: 1818NorCal OAUG Training DayNorCal OAUG Training Day
Appendix – Example of eFabless Rule
Date: January 17, 2007Slide: Slide: 1919NorCal OAUG Training DayNorCal OAUG Training Day
Appendix – Example of eFabless Rule
Date: January 17, 2007Slide: Slide: 2020NorCal OAUG Training DayNorCal OAUG Training Day
Appendix – Example of eFabless Rule
Date: January 17, 2007Slide: Slide: 2121NorCal OAUG Training DayNorCal OAUG Training Day
Appendix – Example of eFabless Rule
Date: January 17, 2007Slide: Slide: 2222NorCal OAUG Training DayNorCal OAUG Training Day
Appendix – Example of eFabless Rule