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What’s New What’s Coming Oracle Process Manufacturing Abhay Satpute, Sr. Director, Oracle Srinivas Puri, Group Manager, Oracle Joan Stevens, Director.

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Presentation on theme: "What’s New What’s Coming Oracle Process Manufacturing Abhay Satpute, Sr. Director, Oracle Srinivas Puri, Group Manager, Oracle Joan Stevens, Director."— Presentation transcript:

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2 What’s New What’s Coming Oracle Process Manufacturing Abhay Satpute, Sr. Director, Oracle Srinivas Puri, Group Manager, Oracle Joan Stevens, Director IT, USDP Dhruba Misra, Oracle Analyst, Paramount Citrus Copyright © 2014, Oracle and/or its affiliates. All rights reserved. |

3 Safe Harbor Statement The following is intended to outline our general product direction. It is intended for information purposes only, and may not be incorporated into any contract. It is not a commitment to deliver any material, code, or functionality, and should not be relied upon in making purchasing decisions. The development, release, and timing of any features or functionality described for Oracle’s products remains at the sole discretion of Oracle. 3

4 Copyright © 2014, Oracle and/or its affiliates. All rights reserved. | Program Agenda Introduction and What’s New Paramount Citrus – Integrating OPM with MES USDP – OPM Quality Sampling & Sequence Dependency What’s Coming Q & A

5 Copyright © 2014, Oracle and/or its affiliates. All rights reserved. | Program Agenda with Highlight Introduction & What’s New Paramount Citrus – Integrating OPM USDP – OPM Quality, Sampling & Sequence Dependency What’s Coming ….. Q & A

6 Copyright © 2014, Oracle and/or its affiliates. All rights reserved. | Oracle Process Manufacturing 6 R12 & beyond: Outside Processing In Memory Yield & Quality Mobile Apps & Table to Tablet Your feedback (Ideation) From : 11i OPM Automated Migration Simplified Maintenance Seamless Flows

7 Copyright © 2014, Oracle and/or its affiliates. All rights reserved. | Our Investments for Modern Manufacturing Profitable OperationsTransformative Insight Ensure Quality Collaboration MES for Process Costing enhancements In-Memory Cost Management Manufacturing 21 Oracle Open World 2014 Open Interfaces Mobile Application Sampling for material moves Quality Endeca Period Close Endeca Transaction Account Register Endeca

8 Copyright © 2014, Oracle and/or its affiliates. All rights reserved. | Manufacturing Execution System Productivity Improvements – Step Release and Complete using operator WB – Auto Commit for Process Instructions – Enhanced Navigation through PI – Batch record continuity from Planning to execution – Process Instruction support for Ad-hoc Operations – Public APIs for MES setup BENEFITS Improve productivity of shop floor operators Increased compliance through standardization Profitable Operations Through Improved Operator Productivity

9 Copyright © 2014, Oracle and/or its affiliates. All rights reserved. | Manufacturing Execution System Step Actions on Operator Workbench Auto Commit for Process Instructions Enhanced Navigation for Process Instructions Retain page display Touch Screen Enhancements

10 Copyright © 2014, Oracle and/or its affiliates. All rights reserved. | Manufacturing Execution System Support for in-process controls for Ad-hoc operation

11 Copyright © 2014, Oracle and/or its affiliates. All rights reserved. | Manufacturing Execution System Create Batch Reschedule Cancel Extended support for Batch Record

12 Copyright © 2014, Oracle and/or its affiliates. All rights reserved. | Costing and Accounting o Parallel Processing Mode OPM Accounting Pre-Processor Wrapper OPM Cost Update o 64 bit executables for Costing Engines Cost Update Process and Accounting Pre-Processor o Options to reduce accounting lines Option to Post Journals at Item Cost or Component Cost Ignore zero amount batch variance accounting lines in OPM Pre Processor Ignore zero amount cost revaluation accounting lines in OPM Pre Processor o Support for large data-sets in cost rollup OPM Financial Enhancements

13 Copyright © 2014, Oracle and/or its affiliates. All rights reserved. | High Performance In-Memory Cost Management Applications Oracle In-Memory Cost Management Cost Impact Simulator and Timely analyses of impact of cost changes Accurately simulate inventory valuations, and impact to margins and profits Gross Profit Analyzer Obtain the most profitable product mix Identify optimal pricing for finished goods Cost Comparison Tool Process and visualize large volumes of data in near real-time Identify the most profitable cost structures Real-time Cost Management for Process Industries

14 Copyright © 2014, Oracle and/or its affiliates. All rights reserved. | Transformative Insights with Endeca Effectively manage period close process – Quickly identify and correct supply chain transactions that are delaying period close – Analyze root cause of bottleneck transactions and initiate corrective measures Ensure accuracy of accounting transactions across sub ledgers – Reconcile accounting transactions posted across multiple sub ledgers to identify discrepancies – Review all accounting entries in the context of any business document before GL posting OPM Costing and Accounting

15 Copyright © 2014, Oracle and/or its affiliates. All rights reserved. | Ensuring Quality Quality visibility through Endeca Automated Sampling for Material Movements Improvements to COA Report Improvements to OPM Quality to Lot Genealogy

16 Copyright © 2014, Oracle and/or its affiliates. All rights reserved. | Sample Dispositions Main Point Lab Management Test Analysis OPM Quality Extensions for Endeca Key Features  Sample dispositions across plants  Quality Metrics  Sample Delays and Tests Due  Expiring Samples  Out of Spec Actions as Tag Cloud  Quality issues from Inventory  Quality Issue with Production  Quality Issues from Suppliers  Alerts……… Solution Overview Quality Issues across sample sources

17 Copyright © 2014, Oracle and/or its affiliates. All rights reserved. | OPM Quality Extensions for Endeca Improve the efficiency of quality lab operations Identify priority of samples to be tested and manage the load Insight into Sample Delays and Tests due Meet manufacturing quality standards and reduce business risk Find and resolve quality rejections as they arise Prevent costly recalls and save company reputation Increase manufacturing yield and reduce cost Establish early control on manufacturing quality deviations Insight into quality issues across Orgs and sample sources

18 Copyright © 2014, Oracle and/or its affiliates. All rights reserved. | Collaborating Batch Open Interface Easily load OPM Batches from outside sources Batch header Import Interface Batch Actions Interface Resource Transactions Interface Purge Import Interface UI For Error Management With Outside Manufacturers and Other Software

19 Prepared by Dhruba Misra Oct 1, 2014 PARAMOUNT CITRUS LLC. Oracle Open World

20 Paramount Citrus is a part of the Roll Global Companies Roll Global LLC is comprised of multiple businesses owned by Stewart and Lynda Resnick. Started by Mr. Resnick 40 years ago, Roll Global has over four billion in assets, over two billion in revenue, employees (worldwide) and is headquartered in Los Angeles. The agricultural businesses are the largest farming operation in North America. Largest grower of almonds, pistachios, and pomegranates in the world Largest integrated grower, packer, and marketer of fresh citrus products in North America Leading technology company specialized in controlled release, pheromone-based products for pest control Largest processor and marketer of pistachios and almonds in the world Largest processor and seller of fresh pomegranates, pomegranate beverages, and related products in the world Largest floral wire service company in the world Largest imported bottled water company in the United States Headquartered in Sydney, Australia and provides shipping services connecting the South Pacific islands to the world New Zealand’s premier Artesian bottled water company Award-winning winery in the Paso Robles appellation in California 20 In the heart of Sonoma Valley wine country, Landmark practices the centuries old tradition of handcrafted wines. This is one of North America's largest grapevine nurseries offering rootstocks, grafted grapevines, clones and more.

21 Our Products

22 22 What Do We Do? Farming and Growing Citrus Varieties Packing of the Harvested crops Shipping and Delivery of Packed Fruits Research and Innovation in Farming, Packing logistics Locations Headquarters: Delano, CA (Central Valley) Offices in Texas, Mexico, California & DCs in Chicago and Albany Facts and Figures 30 million cartons of Fruits shipped worldwide with 30% exports California packing facilities together range more than 1 mil sq ft 400 million pounds of Mandarins packed Wonderful Halos being one of the most popular brands Green Stats 50% of required energy is from green sources 2.7MW solar plant – largest commercially owned solar rooftop 1.6MW fuel cell

23 23 Citrus Oracle Implementation Timeline  Oracle Application version upgraded on Aug 2011  WMS implemented entirely on Mandarin Plant on Oct 2012  WMS Implemented for Finished Goods on Orange/Lemon plant on Sep 2013  Oracle implementation in Texas facilities on Oct 2013  WMS implemented completely in Orange/Lemon plant on Sep 2014 Versions  Database: 11g Enterprise Edition Release bit Production  Oracle Applications :

24 24 Business Process Mapped in Manufacturing Receiving Fruit from Field Storage & De- greening Manual Pick For Pre-Grade Pre-Grade WIP Operation Pack WIP Operation Directed Put away Of Pallets Directed Put away of Sorted Bins WIP Storage Directed Pick For Pack batch Cold Storage Directed Pick Of Pallets Shipping of Sales order Dry Goods Receive & Storage Manual Dry Goods Move to Batch

25 25 Process

26 26 MES Process – WIP Issue and Completion Local Cell Central Cell Custom Interface Oracle Conc. Programs PS WIP Issue / Completion Flow Chart of Interface

27 27  Packout WIP Issue is driven by directed pick  From the legacy MES, the directed tasks (slotting tasks) are generated  LTO scans the equipment for the relevant line, accepts the task and then drops (scans) to the line Pick Strategy Oracle program cancels previous batch’s pending tasks Task Completed Flow Chart of Directed Tasks MES pre-releases batch Oracle program plans and provides available item and quantity based on criteria MES releases the planned Item and quantity Oracle program creates Move Orders for requisite criteria Move Order Pick Slip is submitted Directed Pick Tasks are generated LTO scans the Equipment which is equivalent to line Accepts directed Task, scans bin and drops to line MES Process – WIP Issue and Completion

28 28 Business Benefits Inventory Accuracy >> Space utilization increased by 10% Faster Turn Around >> With the high volume of the product (Halos) an effective handshaking needed between MES and ERP Maintain low product aging >> From 85% to 95+% FIFO compliant Speedy Order Fulfillment >> From 4 hours to 90 min of truck turn-around & each pallet taking 2 min Effective inventory management >> From manual consolidation to automated. Better QC Effective use of Forklift fleet >> Reduced labor hours for monthly physicals vs weekly in pre-WMS

29 29 Challenges Faced Need of more rigor and discipline from operations Transfers of products between WMS and non-WMS orgs Hybrid WMS system in a warehouse before full WMS Issues with LOT to LPN and LPN to LOT conversions Lot Substitution requirement (resolved by Patch :R12.WMS.B)

30 30 Future Plans Full blown Texas WMS Implementation Oracle Implementation in Chicago DC

31 31 Questions

32 Joan Stevens Director, Information Technology

33 Phillips Products Company Phillips Products Company Distiller Sales Products Distiller Sales Products United States Distilled Products United States Distilled Products Consumer Brands Corporate Brands Manufacturing & Logistics USDP International International Sales & Distribution Company Structure

34 Contract Brands Sample of products produced

35 800,000 sq. ft. of facilities in Minnesota, USA 8 Million Cases processed in 2013

36 Transformation Story Custom ERP/AR created over 20 years Financials in JD Edwards – Data reported out of custom ERP/AR and rekeyed into JD Edwards Challenges faced with replacing custom ERP system with Oracle EBS – Regulations around the production/shipping of spirits – Calculating and report of taxes – Scheduling products based on color, flavor, bottle type – Using company knowledge to determine potential forecasts for production

37 Transformation Timeline Aug 2009Oracle EBS v12.1.1: Financials/iExpense Apr 2011Oracle EBS v12.1.1: Oracle Process Manufacturing, Mobile Supply Chain Applications, Purchasing, iProcurement, Order Management, Oracle Advanced Supply Chain Planning (ASCP) – Unconstrained Planning May 2012Oracle Demantra Demand Management v7.3.1 & ASCP Constrained planning project Initiation Nov 2012ASCP Constrained EDD (Enforced Due Date) planning (EBS v12.1.3) Explored set up of sequence dependencies for ASCP in development Jan 2013Launched Demantra and Sales, Operations & Planning (S&OP) process Sept 2013Forecast tuning of Demantra initiated May 2014Re-launched Demantra with significant process changes, additional tuning, changes in worksheets, etc. Nov 2014Convert servers to Oracle Virtual (OVM)

38 OOTB OPM Capabilities Automatic creation of Quality Samples Explored Sequence Dependencies Setup Detailed Routes and Operations to more generic leveraging recipe over-rides for resources Personalization's on batches to control aspects of the batch Lot number controls, reservation warnings, functional restrictions using custom responsibilities Exploring exception codes to control ASCP planning for specific dates and resources. We call it “Block Scheduling” and resources are bottle types Adding routes for all batch types instead of using lead times on the item. This will allow us to move costs from over head to the item using PMAC

39 Production Operations Auto Sample/Lot Status Overview Business Event Triggers Workflow Sample Creation & Notification Approvals Management Engine Notification Routing Test Results Entry Lot Status Updates System Set-up Enable Lot Status Inventory Tests - Specifications - Validity Rules OPM Quality Customers must activate event(s) based on their business reqmts.

40 Production Operations System Set-up USDP Customization Enable Lot Status Inventory Tests - Specifications - Validity Rules OPM Quality Business Event Triggers Custom Workflow Sample Creation & Notification Approvals Management Engine Notification Routing Test Results Entry Lot Status Updates HR Global Roles Tax Determination oracle.apps.gmi.inventory.created event raised by WIP Completion

41 Background: Initially implemented EBS using ASCP Unconstrained planning Planners relied heavily on spreadsheet and internal knowledge to create a schedule Schedule is based on a bottle rotation For ex. A bottle change is needed because of a change in the liquor going into a bottle (line change) or because the bottle itself changes (rotations). The key expectations were –  Reduce capacity lost due to changeovers  Maximize on time demand satisfaction  Better/Optimal scheduling Explored: Use of Enforced Capacity Constraint (ECC) plan leveraging SDS Sequence Dependencies

42 Discovered: Set up of matrix for the routes and operations was complex because of how we initially set them up USDP couldn’t accept the plan batch dates that SDS was recommending because of our requirement for bottle rotations Current state: Kept all documentation related to setting up SDS Using enforced due date (EDD) plan Created generic routes to simplify setting up SDS in the future Exploring exception codes to control ASCP planning for specific dates and resources. We call it “Block Scheduling” and resources are bottle types. Combining this with SDS should give us optimal bottle rotation plan Sequence Dependencies

43 Background: Planning is based on the number of bottles per minute (BPM) that we can complete for Finished Goods (FG) Many different factors go into determining the BPM: For example, some of the liquids need to have different BPM’s even if it is going into the same bottle type on the same line as another product, label application on the bottle impacts speed, etc Each line has a maximum capacity of the number of bottles it can fill per minute Some products can run on a secondary line if needed Initially implemented one or more routes and operations per FG item produced Current state: After exploring SDS determined we needed to make our routes Found that recipe over rides for resources would allow us to control the BPM for a specific item to accommodate the factors identified above This produces a better plan recommendations with less maintenance Generic Routes/Operations

44 Background: Make to stock organization based on forecasts from Demantra and order demand We minimize the number of line changes for a bottle by following a specific rotation of bottle types every X number of weeks Evaluating the capability of leveraging Exception Codes and date ranges to create this rotation within planning Current state: Still in the process of evaluating, but initial test are extremely positive this will meet our needs. Once this is implemented, we will look at SDS again to see if it can improve upon this even more Block Scheduling

45 Future Feb 2015Upgrade to Leverage Quality Module more than it is today for other departments Apr 2015Implement analytics: Financials, Supply Chain, Manufacturing and Procurement/Spend 2016Upgrade to 12.2

46 Contact information: Joan Stevens Questions?

47 Copyright © 2014, Oracle and/or its affiliates. All rights reserved. | Applications Unlimited - Continuing Innovation Oracle E-Business Suite – Strategy and Roadmap 1.User Experience Innovation 2.Functional Innovation 3.Operational Efficiency Ongoing Investment Priorities x.y Sep’13Dec’13Aug’ May’09Dec’09Aug’ Jan’07Dec’08 New Releases For & EBS Extensions for Oracle Endeca Smartphone Applications In-Memory Applications

48 Copyright © 2014, Oracle and/or its affiliates. All rights reserved. | Mobile Process Production Supervisor 48 Batch Infotile Search Batches or barcode scan to view them View batches and steps detail Perform batch actions like release, complete View material issue and resource detail Manage exceptions like unallocated ingredients, expiring lots Collaborate in context using device features Monitor Batches and Take Action

49 Copyright © 2014, Oracle and/or its affiliates. All rights reserved. | Mobile Process Production Supervisor Easily view batches progress and exceptions Search or barcode scan batches Check the batch details Quickly take action on the batch 49

50 Copyright © 2014, Oracle and/or its affiliates. All rights reserved. | E-Business Suite Outsourced Manufacturing Solutions OPM Approach: V1 : Outsourcing at Operation / Step Level Comprehensive Support for Multi-Tiered, Mixed-Mode Outsourcing OEM RMS B C MP Buy Components Virtual Sale of Components B C Virtual Buy of Assembly A B C A Drop Ship Components OEM RMS B C MP Buy Components Sell Components (with Markup) B C Buy Assembly A B C A Drop Ship Components OEM RMS B C MP Buy Components Ship Components B C Receive Assembly A B C A Drop Ship Components OEM MP B C A Process In-house Process Outside Process In-house Manufacture Assembly Ship PFA Receive PFA Ship PFA Receive PFA Process

51 Copyright © 2014, Oracle and/or its affiliates. All rights reserved. | System Flow Diagram for OSP Create OSP Item, Resource, & Batch Step Create and Release PO Line Create Purchase Requisition Complete Batch Step OPM Procurement Release Batch Step requiring OSP OPM Supports outsourcing of service, where material shipment tracking is not required. Creation of Purchase Requisition allows cross referencing the Batch Step Number. PO Line is Batch Step Number aware at all times, as it is created from the same Purchase Requisition. Batch Step can be queried at any time to inquire about receipt of PO Line. Procurement OPM

52 Copyright © 2014, Oracle and/or its affiliates. All rights reserved. | OPM – Outside Processing : Setups OSP Item Generic Resource Plant Resource Sourcing Rules Batch Parameters

53 Copyright © 2014, Oracle and/or its affiliates. All rights reserved. | OPM – Outside Processing Automatic or Manual creation of Purchase Requisitions/Purchase Orders at various batch/step stages To identify the step for outside processing and payment of services according to either number of units/products or resource usage hours Synchronization of Batch and Purchase Order Changes o Batch quantity and date changes to be propagated to PO Costing of the OSP resources either at Standard Cost or PO price OPM Outside Processing Report to view various batches with OSP steps and corresponding PO details Quality inspections for Outside Processing Oracle Confidential – Internal/Restricted/Highly Restricted53 Key Features – V1

54 Copyright © 2014, Oracle and/or its affiliates. All rights reserved. | OPM – Outside Processing Material Shipment and Shipment Document Ability to open PO from Batch Detail Window Partial Material Shipment Ability to track the delay in procuring/receiving the OSP Automate the manual creation of PO through Concurrent Program Workflow Notifications Multiple Outside Processing Steps per Batch Endeca Extension Oracle Confidential – Internal/Restricted/Highly Restricted54 Features for V2

55 Copyright © 2014, Oracle and/or its affiliates. All rights reserved. | What’s Coming … Continued Master Data Execution Process Parameter entry and visibility Material transaction subinventory rules and backflushing Quality Quality Specifications for Item category, Organization striping & security Touch and Tablet friendly Quality Transaction UI Oracle Confidential – Internal/Restricted/Highly Restricted55 Your Inputs Mass Search & Replace Simulator / Optimizer computation fine tuning

56 Copyright © 2014, Oracle and/or its affiliates. All rights reserved. | Analyzing Manufacturing Yield & Quality Data acquisition, streaming, filtering, alerting, exception processing, workflow Interoperability across different data management and analytic technologies 56 Information architecture for qualityExpanded data processing capabilities Improved analytical capabilitiesOptimized infrastructure Comprehensive, scalable, and flexible data models and metadata Modular capabilities supporting rapid evolution and test and learn processes Data discovery, mining, visualization and predictive analytics tools for your manufacturing issues High interactivity user interface and workflows tailored to data scientists and business users Cost effective and optimized storage (NoSQL, HDFS, relational) for all data: structured, unstructured, parametric, non-parametric. Scalable hardware infrastructure In-Memory database and technologies

57 Copyright © 2014, Oracle and/or its affiliates. All rights reserved. | Oracle In-Memory Yield Management Oracle Open World Maximize yields, Optimize Quality Statistical Quality Analysis Monitoring key manufacturing process parameters to enable timely correction to the process and perform rapid root cause analysis of defects, scrap, rejects and rework Yield, Cost and Defect Monitoring Timely tracking and analysis of detailed operation yield, yield costs, variances, and defects as the product undergoes transformation through the various stages of manufacturing Genealogy Traceability End-to-end tracking and analysis of material composition, test results, and process undertaken at every step of the manufacturing process to allow complete traceability of a partially or completely finished product Advanced Analytics Analyze manufacturing big data from the shop floor and correlate event streams across multiple sources to detect patterns and predict potential options to maximize yields, minimize defects, alert downstream risks and suggest corrective actions Comparative Analysis & Simulations Easily compare current and historical manufacturing, quality, and process parameters across products, production lines, and manufacturing/test locations. Visualize similarities and differences in a simple and intuitive manner.

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