Presentation is loading. Please wait.

Presentation is loading. Please wait.

1 Training on 11i.10 enhancements for Infosys 5 th January 2005 Oracle Process Manufacturing.

Similar presentations


Presentation on theme: "1 Training on 11i.10 enhancements for Infosys 5 th January 2005 Oracle Process Manufacturing."— Presentation transcript:

1 1 Training on 11i.10 enhancements for Infosys 5 th January 2005 Oracle Process Manufacturing

2 Agenda  Process Manufacturing  OPM Positioning  Introduction to OPM  Enhancements  Future Direction  Questions and Answers

3 Process Manufacturing Market Profile Beverages, Foods 34% Paper, Metals, Fibers, Earth Products 20% Chemicals, Pharmaceuticals 46% Discrete Process 40% Industry Focus – Pharmaceutical & Biotechnology – Food & Beverage – Chemical – Metals & Paper – Building Materials

4 Variability and The Supply Chain Process - it kind of works Discrete - it works

5  Process Manufacturing Uses Formulas Mixes, Blends, Transforms Makes “STUFF” Making “Stuff” vs. “Things” Process Manufacturing and Supply Chain  Discrete Manufacturing Uses Bills of Materials Builds, Assembles, Fabricates Makes “THINGS”

6 The Physical Inventory Test Count the computers, count the coffee One Cup, OZ, CC, ML, inches… % coffee (cream and sugar?) % Coffee Solids Cup, OZ, CC, ML, inches… % coffee (cream and sugar?) % Coffee Solids Discrete Assumptions vs. Process Realties

7 Material Changes With Time  Discrete Assumption – Constant through time  Process Realities – Varies through time Time

8 How Different are they?  Parts to Ingredients  BOMto Formula  Each to Batch (Bulk)  ReworktoRecycle  ScraptoByproduct  UOMto Multiple UOM  ConstanttoVariability  SpecificationtoAttributes

9 Discrete Item Number Location Quantity Simple Process Item Number Location Quantity Unit of measure Tank/silo Lot number Aging information Classification Complex Process Item Number Location Quantity Unit of measure Tank/silo Lot number Sub-lot number Container ID Container type Aging information Catch weight Classification Quality Hazards Information

10 Bill of Material Assumptions  Many components make one end item – The “A Bill”  Predictable in what is made – A + B always = AB  Predictable in how much is made – 1+1 always = 2  Always made the same way

11 Bill of Material Assumptions  Many components make one end item – The “A Bill”  Predictable in what is made – A + B always = AB  Predictable in how much is made – 1+1 always = 2  Always made the same way many and the V, X and I bills NO! A + B hopefully = AB Not 1+1 approximately = 2 NO! Fresh vs. frozen ingredients, quality, line, seasonal differences, etc. And Process Realities

12 Variability in Process Manufacturing Potency % Solid Multiple Units of Measure pH Factor Multi-Plant Manufacturing Fluctuating Commodity Prices Complex Costing Alternative Routings Alternative Formulas Sequencing Quality Attributes Grade Status Catch Weight Lot Sizes Yields Shelf Life Seasonality Viscosity Toxicity

13 Unique Process Requirements Formula Management Co-Products & By-Products Unit of Measure Conversion Quality Specifications & Control Lot Control Ageing & Expiry Yield & Loss Factors - No Scrap!

14 Unique Process Requirements  Lot Traceability  Packaging  Regulations – FDA & MSDS  Sub Lot Requirements  Catch Weight  Scheduling Needs

15 Agenda  Process Manufacturing  OPM Positioning  Introduction to OPM  Enhancements  Future Direction  Questions and Answers

16 Business Pressures Variability How do I create consistent products using inconsistent ingredients? How do I achieve process and reaction stability? Variability How do I create consistent products using inconsistent ingredients? How do I achieve process and reaction stability? Regulatory Compliance How do I comply with global and local requirements? How do I ensure lot traceability and adhere to standards such as 21 CFR Part 11? Regulatory Compliance How do I comply with global and local requirements? How do I ensure lot traceability and adhere to standards such as 21 CFR Part 11? Reduced Time to Market How can I manage a growing list of key product attributes? How can I efficiently mass customize my products? Reduced Time to Market How can I manage a growing list of key product attributes? How can I efficiently mass customize my products? Lowest Total Cost How can I meet quality, delivery, and service demands at a competitive price? Lowest Total Cost How can I meet quality, delivery, and service demands at a competitive price? Raw Materials, Ingredients Value-Added Transformation Finished Goods

17 Operational Challenges PROCESSING PLANT Material push R&D LAB Finished Goods Materials Inventory CUSTOMERS SUPPLIERS Documentation required at every step for traceability & compliance No status visibility between supply chain partners Inefficient material and capacity utilization Documentation required at every step for traceability & compliance No status visibility between supply chain partners Inefficient material and capacity utilization Materials, Ingredients, Quality Docs Finished Goods, Quality Docs Waste Step 10 Step 20 Step 30 Step 40 Step 50 By- / Co- Products Limited joint development with poor recipe reuse High variability in release-to- volume-production process

18 Computer Assisted Recipe Formulation Process Flexibility with Rapid Changeover Renewed Emphasis on Product Safety & Traceability Increasing Collaboration with Suppliers Continued Focus on Cost Containment Computer Assisted Recipe Formulation Process Flexibility with Rapid Changeover Renewed Emphasis on Product Safety & Traceability Increasing Collaboration with Suppliers Continued Focus on Cost Containment A Need for Change Leading Business Trends

19 Suppliers Customers Finished Product Mfgr Distribution Channels RawMaterials Process Industry Value Chain Distributors Growers Manufacturers Business Consumer Web Direct Brand Dev. MarketingResearch Product Dev. Manufacturing Retailers

20 Oracle: Built for Process Industries Data Server Applications Server Source Process Manufacture Process Manufacture Fulfill Service Develop Plan Market Sell Finance HR Projects Finance Maintenance Customer Relationship Management Supply Chain Management

21 OPM for the Industries

22 OPM Customers

23 Consumer Goods Capabilities Evolution of Oracle Applications in Consumer Goods Current Differentiators… Mixed Mode Manufacturing Inventory Postponement Optimization Supplier Collab & VMI Collaborative Planning Supply Chain Exception Mgmt Real Time Order Promising and Visibility Multi-Channel Order Capture Advanced Pricing EDI Transactions for POs, Ship Notices, Invoicing & Warehousing Claims & Deductions Mgmt Lot Traceability Funds Management Promotional Planning Mixed Mode Manufacturing Inventory Postponement Optimization Supplier Collab & VMI Collaborative Planning Supply Chain Exception Mgmt Real Time Order Promising and Visibility Multi-Channel Order Capture Advanced Pricing EDI Transactions for POs, Ship Notices, Invoicing & Warehousing Claims & Deductions Mgmt Lot Traceability Funds Management Promotional Planning …new in 11i.10 …with 11i.9… Process Manufacturing – 21 CFR Part 11 Compliance – HACCP Quality Test Points – Automatic Lot Grading – Manufacturing Scheduler High Volume Order Processing Continuous Real-Time Demand Planning Integrated Maintenance and Production Planning Enhanced Blanket Orders and Releases Retroactive Promo Adjustments Promotional ROI Calculations 3 rd Party POS Data Import (to Calc Promotional Accruals) Transportation Execution Collaborative Sourcing Advanced Product Catalog Process Manufacturing – 21 CFR Part 11 Compliance – HACCP Quality Test Points – Automatic Lot Grading – Manufacturing Scheduler High Volume Order Processing Continuous Real-Time Demand Planning Integrated Maintenance and Production Planning Enhanced Blanket Orders and Releases Retroactive Promo Adjustments Promotional ROI Calculations 3 rd Party POS Data Import (to Calc Promotional Accruals) Transportation Execution Collaborative Sourcing Advanced Product Catalog Product Information Hub with UCCNet Support (11i.10+) Discrete Manufacturing – 21 CFR Part 11 Compliance RFID Transactions Short Term Deployment Planning Transportation Planning Scarce Inventory Allocation Enhanced Trade Mgmt. Tools Business Account Planning Integrated Sales Contracts Quick Ship User Interface Customer Consigned Inventory Retroactive Pricing in Purchasing Channel Budget Management Enhanced Management and Resolution of Promotional Claims Product Information Hub with UCCNet Support (11i.10+) Discrete Manufacturing – 21 CFR Part 11 Compliance RFID Transactions Short Term Deployment Planning Transportation Planning Scarce Inventory Allocation Enhanced Trade Mgmt. Tools Business Account Planning Integrated Sales Contracts Quick Ship User Interface Customer Consigned Inventory Retroactive Pricing in Purchasing Channel Budget Management Enhanced Management and Resolution of Promotional Claims Oracle confidential. This is not a commitment to deliver. Product directions are subject to change without notice.

24 OPM Consumer Goods Customers

25 Life Sciences Capabilities *CRF = Case Report Form …with 11i.9… 21 CFR Part 11 Compliance for Process Manufacturing – Electronic Signatures – Electronic Records Validation Procedures Production Batch Record Keeping System Integrated Process Quality Workbench Advanced Product Catalog CRF* Design and Layout Utility Direct Entry on PDF Forms- Enabled CRFs Multi-Lingual Remote Data Capture Entry & Monitoring 21 CFR Part 11 Compliance for Process Manufacturing – Electronic Signatures – Electronic Records Validation Procedures Production Batch Record Keeping System Integrated Process Quality Workbench Advanced Product Catalog CRF* Design and Layout Utility Direct Entry on PDF Forms- Enabled CRFs Multi-Lingual Remote Data Capture Entry & Monitoring Current Differentiators… Clinical Trials Data Mgmt Adverse Event Reporting Thesaurus Management Clinical Remote Data Capture Skills Database Process Manufacturing – Potency Support – Expiration Dating – Industry Compliant Recipes Lot Traceability Genealogy Project Management Flow Manufacturing Inventory Optimization Workflow-Enabled Quality Management Clinical Trials Data Mgmt Adverse Event Reporting Thesaurus Management Clinical Remote Data Capture Skills Database Process Manufacturing – Potency Support – Expiration Dating – Industry Compliant Recipes Lot Traceability Genealogy Project Management Flow Manufacturing Inventory Optimization Workflow-Enabled Quality Management …new in 11i.10 Computer-Aided Formulation Stability Studies Management Environmental Testing E-Signatures on Documents Graphical Recipe Designer Mass Quality Control Result Entry Multiple Drum Receipt with Automatic Lot Numbering Enhanced Management & Resolution of Chargebacks Procurement Contracts RFID-Based Transactions Computer-Aided Formulation Stability Studies Management Environmental Testing E-Signatures on Documents Graphical Recipe Designer Mass Quality Control Result Entry Multiple Drum Receipt with Automatic Lot Numbering Enhanced Management & Resolution of Chargebacks Procurement Contracts RFID-Based Transactions Evolution of Oracle Applications in Pharma / Biotech Oracle confidential. This is not a commitment to deliver. Product directions are subject to change without notice.

26 Oracle Life Sciences Customers

27 Chemicals Capabilities Current Differentiators… …new in 11i.10 …with 11i.9… Product Development for Process Manufacturing Laboratory Spreadsheet and Formula Analysis Dual Unit of Measure for Active Ingredients Shelf-Life & Status Control Co- / By-Products Lot Traceability Shift Level Reporting Asset Maintenance Supply Chain Planning and Procurement EDI Transactions for POs, Ship Notices, Invoicing & Warehousing MES Integration APIs Multi-Channel Order Capture Real Time Order Promising and Visibility Product Development for Process Manufacturing Laboratory Spreadsheet and Formula Analysis Dual Unit of Measure for Active Ingredients Shelf-Life & Status Control Co- / By-Products Lot Traceability Shift Level Reporting Asset Maintenance Supply Chain Planning and Procurement EDI Transactions for POs, Ship Notices, Invoicing & Warehousing MES Integration APIs Multi-Channel Order Capture Real Time Order Promising and Visibility Process Industry Procedures and Business Flows for ISO Certification 21 CFR Part 11 Compliance Sequence Dependent Scheduling Quality-Driven Lot Usage and Production Control Product Data Management via Process Parameters Continuous Real-Time Demand Planning Integrated Maintenance and Production Planning Transportation Execution Collaborative Sourcing Advanced Product Catalog Enhanced Blanket Orders and Releases Process Industry Procedures and Business Flows for ISO Certification 21 CFR Part 11 Compliance Sequence Dependent Scheduling Quality-Driven Lot Usage and Production Control Product Data Management via Process Parameters Continuous Real-Time Demand Planning Integrated Maintenance and Production Planning Transportation Execution Collaborative Sourcing Advanced Product Catalog Enhanced Blanket Orders and Releases Computer-Aided Formulation Stabilities Studies Mgmt Reserve Manufacturing to Sales Orders Rapid Recipe Creation Lot-Specific Costing Environmental Monitoring Enhanced Co-Product Planning Transportation Planning Short Term Deployment Planning Customer Consigned Inventory Integrated Sales Contracts Retroactive Pricing in Purchasing Business Account Planning Channel Budget Management Computer-Aided Formulation Stabilities Studies Mgmt Reserve Manufacturing to Sales Orders Rapid Recipe Creation Lot-Specific Costing Environmental Monitoring Enhanced Co-Product Planning Transportation Planning Short Term Deployment Planning Customer Consigned Inventory Integrated Sales Contracts Retroactive Pricing in Purchasing Business Account Planning Channel Budget Management Evolution of Oracle Applications in Chemicals Oracle confidential. This is not a commitment to deliver. Product directions are subject to change without notice.

28 OPM Chemical Customers

29 The Process Manufacturing Marketplace Suite Vendors: offer integrated suite Niche Players: claim “best-of-breed”, but require large integration efforts

30 Source: AMR February 2004 The Bottom Line: Food, Consumer Products, Chemicals, and Life Sciences customers now have a single vendor product that can span their requirements for Process Enterprise Resource Planning (ERP), Enterprise Asset Management (EAM), Supply Chain Management (SCM), and Product Lifecycle Management (PLM). Recent Process Press

31 Source: Gartner In terms of industries again, Oracle's greatest penetration according to Gartner is in the manufacturing segments, and with a 7.4% growth in Process Manufacturing actually slightly outgrew SAP Recent Process Press

32 "Oracle now leads in overall process ERP depth and flexibility." - Meta Group (2004) Recent Process Press

33 -AMR 2004 Oracle is setting the new Process ERP benchmark by extending Process industry functionality into its full E-Business Suite. This addresses the full checklist of capabilities that we suggest customers assess from their ERP vendors Recent Process Press

34 How Process Mfg Solutions Stack Up... o-oo Activity-Based / Lot Costing +-++ Multiple Simultaneous Cost Methods -o++ Proactive Quality Workflows --++ Formula-Based MSDS Development ++o+ Multi-Level Lot Traceability +-o+ Recipe Rules-Based Production Ross/CDCSCTSAPOracle Capability Notes: + = Good, o = Neutral, - = Poor

35 How Process Mfg Solutions Stack Up Integrated Catch-Weights +-o+ Complex Process Modeling --++ Electronic Signatures +-++ Step-Level Production Mgmt ++o+ Potency Allocations Ross/CDCSCTSAPOracle Capability Notes: + = Good, o = Neutral, - = Poor

36 Top 5 reasons cited for not using SAP R/3 Manufacturing 94 % of SAP process manufacturing customers cited Lacking functionality as number 1 reason for not using SAP manufacturing 94 % of SAP process manufacturing customers cited Lacking functionality as number 1 reason for not using SAP manufacturing

37 Agenda  Process Manufacturing  OPM Positioning  Introduction to OPM  Enhancements  Future Direction  Questions and Answers

38 Oracle Manufacturing Product Family Process Mfg. Fulfill Mai ntai n and Ser vice Order Management Configurator Advanced Pricing Release Management Inventory Management Warehouse Management Transportation DesignPlanProcure Advanced Supply Chain Planning Inventory Optimization Global Order Promising Demand Planning Collaborative Planning Constraint Based Optimization Purchasing iProcurement Sourcing iSupplier Portal Oracle Supplier Network Procurement Intelligence Procurement Contracts Services Procurement Advanced Product Catalog CAD View 3D Product Intelligence Process Inventory Product Development Process Execution Process Planning Costing and MAC Process Quality Regulatory Mgmt OPM System Admin ERES Enterprise Asset Management Complex Maintenance, Repair & Overhaul CRL Financial Management Network Logistics (Network Asset Tracking)

39 Customers Product Development Product Specifications New Product Required Product Exists Order Management Product Costing Optimized Formula Approved APS / MRP Should Product be Produced? Order Procurement Requisition Raw Materials Suppliers Inventory Receive Supplier Lots Production Schedule Batches Trace Lots Quality Management Match Customer Specs Submit for Analysis Ship Product by Grade OPM Understands your Business Flows...

40 Launch Plant Trials Pilot Develop OPM Product Development Research Experimental Recipes Collaborate Lab Batches Regulatory Documents What-if Analysis Workflow Based Approvals Production Recipes A secure, configurable environment for bringing new products to market

41 OPM Product Development Solution Secure and Manage Data Formula Security, Product Development Workbench, Product Lifecycle Management Define and Enforce Business Practices Change Management, Workflows, Process Parameters and Process Instructions, E-records and E-signatures Accelerate Recipe Development Recipe Designer, Default Status, Auto-Recipe Generation, Mass Search & Replace Reduce Costs and Optimize Formulas Simulator & Optimizer, Formula Analysis

42 Item Warehouse Location Lot Sublot Status Grade/Spec Multiple UOM Precise Inventory Tracking  Shelf life  Retest interval  Potency  User-defined classifications Quality Driven Product Attributes Manage Variability / Sustain Product Consistency 9FA F (Aurora Whse) Aisle 1, Row 1 Level 1 (1-1-1) Day Code; Batch #; Prod Run Pallet; Case ID Good/Hold/Reject A LB/EA

43 OPM Multiple Units of Measure  Package / Liquid / Solid contents can vary by containers  Track onhand inventory in two units of measure simultaneously  Formulate and Transact in any convertible UOM Standard: 1 Case = 10 LB 20.0 LB vs Lot 001- A 1 Case = 10.5 LB Lot 001- B 1 Case = 10.3 LB 20.8 LB

44 Multi-Level Material/Resource Traceability Reduce Risk to Public Health and Brand Image Improve Recall Responsiveness / Cost Comply with FDA GxP and Safety Regulations Trace Materials Enterprise-Wide to Analyze Quality Ingredients & Resources Intermediate or Bulk Products Finished Product SupplierConsumers Where Used Lot Source

45 Oracle Process Inventory Solution Satisfy Customer Demand Quickly and Accurately Quality-Driven Product Attributes, Multiple UOM Control, Auto Allocation, Lot Expiration Management, Grade and Status Reduce Costs with Efficient Inventory Management Physical Inventory and Cycle Counting, APIs, Inquiries and Reports Reduce Risk with Rapid Lot Genealogy Analysis Lot Genealogy Inquiry, Report and Business Intelligence Ensure Regulatory Compliance Audit Trail, Strong Security, Electronic Recordkeeping with Electronic Signatures for 21 CFR Part 11 Compliance

46 Oracle Process Manufacturing – MRP The Planning Process Demand ForecastCustomer order Dependent demand Transfer out Supply InventoryPurchase order ProductionTransfer in Production schedule Material requirements plan

47 Oracle Process Planning MRP Solution Balance supply and demand Consider all sources of supply and demand Applies demand to current inventory balances Consider lot expiration of current inventories Suggests specific actions based on user defined rules Purchase, transfer, and production suggestions Projects inventory availability dates based on MRP recommendations Process Planning reports

48 Ingredient 2 Ingredient 1 10 Dispense Resource+ActivityUsage/Qty By-Product 1 Ingredient 4 30 Blend Resource+ActivityUsage/Qty Product 1 Ingredient 5 40 Package Resource+ActivityUsage/Qty Ingredient 3 20 Weigh Resource+ActivityUsage/Qty Start-to-Start Finish-to-Start QC step HOLD ERESWF ERES Batch Processing Checks Required e-signatures and QC test completion

49 Quality-Controlled Batch Processing Control Production Variability with Quality Checks Hold Step for Quality Sampling and Testing 10 Weigh 30 Blend 40 Package 20 Heat E-Sign Resource+ActivityUsage/Qty Resource+ActivityUsage/Qty Resource+ActivityUsage/QtyResource+ActivityUsage/Qty E-Sign E-Sign E-Sign E-Sign

50 Oracle Process Execution Solution Maximize production flexibility Flexible scaling Increase plant efficiencies ASCP, Gantt Chart, Automatic lot allocation Streamline reporting using backflushing and API’s Incremental backflushing, over 40 API’s Achieve product consistency Simulator/Optimizor, Process Parameters, Processing Instructions, Quality Testing, Electronic Records

51 Workflow-Driven Processes and Electronic Records StandardizeSampleAnalyzeDispositionReport Oracle Process Manufacturing Quality Manage Variability and Assure Product Consistency Inspection Points Receipt, WIP, shipping Lot expiration/retest Environmental monitoring Inspection Points Receipt, WIP, shipping Lot expiration/retest Environmental monitoring Global Standards Tests & methods Sampling plans Specifications Input APIs Global Standards Tests & methods Sampling plans Specifications Input APIs Compliance Certificate of analysis or conformance Lot genealogy Electronic recordkeeping Compliance Certificate of analysis or conformance Lot genealogy Electronic recordkeeping Results Composite result statistics (min/max, std dev, average) Stability studies Output APIs Results Composite result statistics (min/max, std dev, average) Stability studies Output APIs Integrations Material usage decisions based on lot status and grade Order allocation (based on results) Quality-controlled batch processing Integrations Material usage decisions based on lot status and grade Order allocation (based on results) Quality-controlled batch processing Adjust batches Change formulation or procedures Adjust batches Change formulation or procedures Process Improvement

52 Workflow-Driven Quality Management Automate quality tasks and reduce lead times Require Material Inspection based on Specifications Sample Creation Notification Workflow Create Samples Testing Notification Workflows Enter, Evaluate, Composite Results MSDS Test Results Samples Disposition Workflow Update Item Lot Status/Grade

53 Oracle Process Quality Solution Achieve product consistency Stability studies, lot expiration handling, batch control Enforce proactive quality assurance Specification validity rules, sampling, environmental monitoring, workflow, e-record and e-signatures Streamline quality lab productivity Automated test/lab assignment, Quality workbench Assure customer and regulatory compliance Customer spec matching, Certificates of Analysis, lot traceability

54 Oracle Process Manufacturing Costing Support All Phases of Costing Cost Development MonitoringAllocationAnalysisValuation Indirect Acquisition Overhead Resource Material ActualLotStandard Composite

55 Multiple Costing Methods Supports different costing needs Standard Costing Actual Costing Lot Costing Calculates based on formula and routing cost rollups Calculates based on actual production data and allocations Calculates based on actual production data for a specific lot

56 Oracle Process Financials Solution Optimize Costs & Margins Multiple cost methods: Standard, Actual, Lot, Composite, Cost Development Workbench Capture precise product costs Co-products, by-products, circular references, unlimited cost elements, cost allocations Facilitate proactive cost management Cost monitoring, cost analysis Assure proper accounting of Resource & inventory transactions Flexible account mapping, Sub-ledger flow, Drill Downs

57 Evolution of Oracle Process Manufacturing …with 11i.9… Current Differentiators… Collaborative, rules-based recipe development Ingredient and process variability management Optimized capacity and ingredient usage Multiple cost methods Pre-defined quality workflows Supplier & customer collaboration Real-time WIP visibility Lot traceability Co-products & by-products Shelf-life and status control Expiration dating Potency support Collaborative, rules-based recipe development Ingredient and process variability management Optimized capacity and ingredient usage Multiple cost methods Pre-defined quality workflows Supplier & customer collaboration Real-time WIP visibility Lot traceability Co-products & by-products Shelf-life and status control Expiration dating Potency support … new in 11i.10 Integrated process quality workbench Manufacturing scheduler with process production Electronic signatures and records for 21 CFR part 11 Process industry tutor procedures and business flows Detailed shop floor data management Validation procedures Production batch record keeping system Automatic lot grading HACCP quality test points Integrated process quality workbench Manufacturing scheduler with process production Electronic signatures and records for 21 CFR part 11 Process industry tutor procedures and business flows Detailed shop floor data management Validation procedures Production batch record keeping system Automatic lot grading HACCP quality test points Graphical recipe designer Lot specific costing Computer-aided formulation Electronic records and signatures document control Enhanced customer quality specification matching Mass quality control result entry Enhanced co-product planning (via advanced planning integration) Environmental testing Multiple drum receipt with automatic lot numbering Graphical recipe designer Lot specific costing Computer-aided formulation Electronic records and signatures document control Enhanced customer quality specification matching Mass quality control result entry Enhanced co-product planning (via advanced planning integration) Environmental testing Multiple drum receipt with automatic lot numbering

58 Agenda  Process Manufacturing  OPM Positioning  Introduction to OPM  Enhancements  Future Direction  Questions and Answers

59 Topics  Process Inventory  Product Development  Quality Management  Regulatory Management  OPM System Administration  Process Planning  Process Execution  Process Costing  Process Logistics

60 Process Inventory Process Inventory

61 New Feature Highlights Process Inventory  Lot UOM Conversion Update  Automatic Lot Numbering Configuration  Process to Discrete Inventory Transfer

62 Lot UOM Conversion Update  Lot UOM Conversions can be updated if: – Pending transactions do not exist for lot – No unposted Journal transactions exist for lot – User has access to this function – User has organization security for warehouse where lot is onhand  Onhand inventory can be updated – Tracked via inventory transaction (CONV)  Audit of lot UOM conversion changes is tracked

63 Auto Lot/Sublot Numbering  Configurable by item  User-defined lot and sublot prefix  Manual override allowed  Suffix can be reset to fill in numbering gaps  Custom schemes supported via program exit  Zero pad option  “Smart” sublot suffix – Sequential for a lot – Resets for new lot

64 Process-Discrete Inventory Transfer

65 Process-Discrete Inventory Transfer  New form to transfer inventory between OPM organization and Discrete organization  Controlled release

66

67

68

69 Product Development Product Development

70  Graphical Recipe Designer  Automatic Recipe Generation  Computer Aided Formulation  Mass Search and Replace for Recipe Validity Rules  Default Status Generation New Feature Highlights Product Development

71 RecipeDesigner

72 Recipe Designer – Designed for formulators and process engineers – Enables creation and maintenance of Recipes – User friendly interface

73 Automatic Recipe Generation

74 Upon creating a Formula, a Recipe and Validity Rule(s) are generated based on user-defined rules Formula Recipe + Validity Rules generates

75

76

77

78

79 Computer Aided Formulation

80 Computer-Aided Formulation Model Production Requirements to Target Specifications Product Recipe Target Product / Customer Specs Recalculate Material and Yield Quantities Compute Batch Characteristics (e.g., fat content, potency, etc.) Allocations Automatically Revise Lot Allocations Recalculate Material and Yield Quantities Compute Batch Characteristics (e.g., fat content, potency, etc.) Allocations Automatically Revise Lot Allocations Computer-Aided Formulation Optimize Lot Usage / Production Batch Properties Use “What if” Simulation to Streamline Production Planning In-Process QC Metrics Inventoried Lot Properties

81

82

83

84

85

86

87

88 Calculated based on the ingredient parameters

89 Formula or Batch Optimization

90

91

92

93 Optimization results

94

95 Mass Search and Replace

96

97

98

99 DefaultStatus

100

101

102 Quality Management Quality Management

103  Introduced Quality Workbench  Specifications & Sample Monitoring for Non- Material sources  Product Stability Analysis  Automatic Sample Creation  Mass Results Entry & Association New Feature Highlights Quality Management

104 Quality Workbench  Organize specifications and samples data – Summary – Details: Tests, Results  Improve quality laboratory productivity  Simplify access to Quality screens  Personalize workbench with saved queries

105 Monitoring Specifications and Samples  Inspect quality levels of non-material sources: – Warehouses or locations – Generic or plant resources  Notify of out-of-spec conditions via the sample group rejection workflow  Examples of uses: – Monitor environmental controls (e.g. temperature) – Inspect an equipment resource for proper calibration – Validate stability study storage chamber conditions 25°C

106 Stability Study Management  Determine shelf life and recommended storage conditions  Assess environmental impact on material quality  Establish a retest period for similar future batches  Compliance with the US Food & Drug Administration (FDA) and Good Manufacturing Practices (GMP) Batch A Initial Samples Variant A1 Glass 40°C 75% RH months Variant A3 Polyethylene 40°C 75% RH 0 12 months Variant A2 Plastic 40°C 75% RH months  

107 Quality-Driven Lot UOM Conversion  Leverage quality test result(s) to: – Account for lot-to-lot quality variations – Recommend lot-specific inter-class UOM conversions – Notify to update conversions and on- hand inventory

108 AutomaticSampleCreation

109

110 MassResultsEntry

111

112

113

114 Regulatory Management

115 Document Creation to Document Management E-business Suite MSDS Document System Items Properties Formula Sales Info Customer Info Inventory Balance iSign Atrion & Wercs

116 Regulatory Features  Document Storage and Retrieval (iSign) – Document Security – Approvals Management – eRecords and eSignatures  Export APIs – Items – Formulas – Customers – Specifications – Technical Parameters – Item Properties  Re-build Notifications  Electronic Distribution Oracle Files Document Storage MSDSGenerationSoftware SupplierMSDS CustomerMSDS

117 OPM Systems Administration OPM Systems Administration

118 Archive and Purge Archive Process Test RunPurge Process

119 Archive and Purge Implementation Steps – User defined purges  Some setup can be done through Purge Setup form  SQL Statement must be loaded directly to table

120 Process Planning Process Planning

121 OPM Planning OPM MRP OPM- APS

122 Oracle Process Manufacturing MRP is: – OPM MRP is a typical material planning application  Material planning against dependent and independent demand to ensure on-time delivery  No CRP capacity or resource planning (See OPM integration to ASCP, next slide)

123 OPM with ASCP is: – OPM is fully integrated with ASCP to perform material and resource planning using process features such as:  Recipes/Validity Rules  On hand lot expirations  By-products, Co-products  Scaling  MTQ

124 OPM Integrates with APS – Integrated APS products with OPM:  ASCP  Demand Planning  Manufacturing Scheduling  Inventory Optimization  Collaborative Planning

125 OPMMRP

126 New Features for OPM PMRP – Considers lot expiration – Auto release suggestions

127 MRP Material Inquiry showing the expired lot as a negative supply (reducing on-hand to 25)

128 New Concurrent Program to Release MRP suggestions

129 OPM with ASCP

130 New Features for OPM with ASCP – Production Execution enhancements:  Detailed feedback into batches  Preferred effectivity in batch creation  Firm flag on batch – OPM enhancements in ASCP  Shift simulation  Resource exception messages  Bottleneck resources  Auto release of suggestions – In-line forecast consumption – Targeted resource availability

131 Detailed Feedback into Batches – ASCP operation times & dates update OPM batches Planning Execution Shop Floor

132 Preferred Effectivity in Batch Creation – Create the batch with the Recipe/Validity rule selected in ASCP

133 Preferred Effectivity in Batch Creation Feature Overview – OPM APS New Batch – Displays the Effectivity used during planning by ASCP – Create batch using selected recipe or change it Selected Effectivity

134 Firm Flag on Batch – Firming a batch prevents rescheduling by ASCP

135 Shift Simulation – What-if capacity changes can be modeled

136

137

138 Resource Exception Messages – Over & under loaded resource exceptions display in the ASCP workbench

139 Bottleneck Resources – ASCP will constrain only bottleneck resources

140

141

142 Auto Release of Suggestions Full Auto Release – Mass release – check “Production” box on plan Mass release option

143 Auto Release of Suggestions Semi-Auto/Manual Release – Workbench release – check suggestions – Profile: GMP:Auto Implement APS suggestions (YES) Release selected suggestions

144 Auto Release of Suggestions Semi-Auto Release – Enter criteria to create batches – Profile: GMP:Auto Implement APS suggestions (OFF) Enter Parameters

145 In-line Forecast Consumption – Forecast consumption now performed in the APS engine enabling:  Full use of Inventory Optimization  Net Change capability with OPM.

146

147 Targeted Resource – Update resource calendar availability Line 1 Line 2

148

149 Process Execution Process Execution

150  Resource Back Flushing  Support for Shop Calendar setups  Terminate Production Batch New Feature Highlights Process Execution

151 ResourceBackflushing

152 Definition: Backflushing – Reducing the ingredient based on standard formula/routing and the finished goods completed

153 Resource Backflushing Feature Overview – Incremental Backflushing can now be used to backflush resource usage in addition to material usage

154

155

156

157

158

159

160

161

162

163

164

165 Shop Calendar

166 Support for Shop Calendar Feature Overview – Shop Calendar respected in batch creation and rescheduling – Warning if creating a batch to start during non- working time – Calculation of batch duration takes into account non-working time – Option to schedule batch during planned down time for overtime

167

168

169

170 TerminateBatch

171 Terminate Batch Feature Overview – Ability to terminate a WIP batch – Cancels remaining Pending steps – Sets batch status to Completed and sets new “Terminated” indicator – Leaves actual quantities as recorded to that point, but can be adjusted

172

173

174 Process Costing Process Costing

175 New Features of Lot Costing – Track lot cost of raw materials – Merge lot cost (multiple receipts of same lot) – Roll up manufactured lot cost – Lot Cost History Report – Stand-alone Patch

176 Lot Level Costing

177

178

179

180

181

182 Process Logistics Process Logistics

183  Reservation Against Production Workflow  Multi-Lot Receipt  Control on Customer Returns  Auto Allocation Enhancements (Shipment) New Feature Highlights Process Logistics

184 Reserving Against Production

185 Reserve Production for Sales Order – Allows sales order reservations against a Production Batch or Firm Planned Order (FPO) Complete Batch Create Reservation Reservation converted to inventory allocation

186 Reserving Against Process Execution Description – Reserve against Pending and WIP Batches – Reserve against Firm Planned Orders (FPO’s) – Batch completion converts reservations into allocations – FPO reservations convert into batch reservations – Customer Service and Production monitor and modify reservations

187 Reserving Against Process Execution Reservation Rules Setup  (N) Production Supervisor > Sales Order Reservations Time period for which to display batches and FPO’s Allocation Priority for over-allocation

188 Reserving Against Process Execution How to Use this Feature – Create sales orders  Reserve Production to the order – Convert the Firm Planned Order to a Batch  Reservations are converted to batch reservations – Manage changes between sales order and batch – Complete the batch – Pick confirm and ship the sales order

189 Reserving Against Process Execution Reserve Production  (N) Order Management > Orders > Sales Orders User enters reserved quantities This tab shows batches and FPO’s that can be reserved

190 Reserving Against Process Execution Convert FPO to a Batch FPO Reservation is converted to a batch reservation FPO’s can convert into one or more batches

191 Reserving Against Process Execution Monitor Reservations  (N) Production Supervisor > Sales Order Reservations Modify reserved quantity, if needed Find reservations based on sales order or batch

192 Multiple Lot Receiving

193 Receiving Multiple Lots Description – Quick entry of multiple lots in Receiving – Uses automatic lot number generation – Typing aid for users who receive many lots against one Receiving line

194

195

196

197

198 CustomerReturns

199 Controlling Customer Returns Description – Validate lots and sublots for a return – Control level of validation required – Integrates with receipt recorded in Purchasing

200

201

202

203

204 AutomaticAllocation

205 Automatic Allocation Enhancements Description – Match against quality specifications  Allocation rules include use of QC specifications  Uses quality data maintained in OPM Quality  Customer specification matched against lot results – New user interface to run automatic allocation  Accepts parameters to determine inventory  Allows allocation for multiple delivery lines  Handles allocation of inventory after pick release

206

207

208 Agenda  Process Manufacturing  OPM Positioning  Introduction to OPM  Enhancements  Future Direction  Questions and Answers

209 Beyond 11i.10…  Inventory Convergence  Enhance Core Process Modules (Formulation Management, Production, Quality,Costing) – Campaign management – Attribute driven manufacturing – Outsourced manufacturing  Define Process Industries Requirements – Product Life Cycle Management – Inventory / Logistics / Transportation – Planning

210 A Q & Q U E S T I O N S A N S W E R S


Download ppt "1 Training on 11i.10 enhancements for Infosys 5 th January 2005 Oracle Process Manufacturing."

Similar presentations


Ads by Google