Presentation on OPM

Anush Makam Venkatesh

Manufacturing
Discrete Manufacturing
Automobiles, computer, dishwasher and washing machines

Flow Manufacturing
Lean or JIT

Process Manufacturing
Food, pharmaceuticals, etc.

Formulator
The Formula Management module facilitates entering information about how products are manufactured. Formula:
This helps us in pre define the quantities of ingredients we
need to make the product

Process Engineer
Routing:
This helps in define the steps, operations, resources and sequences of all these to make the

product.

Recipe:
This is to combine Formula with Routing and specify when this combination is valid. Formula + Routing Recipe

Formula
Scaling Allowed checkbox is to scale the product and ingredient quantities up & down. Packing checkbox is to just differentiate production formula from packing formula. Calculate Product Quantity: ingredient input quantities and their yields to calculate final product quantity.

Formulator Formulas

Entering Formula Details

Entering Products
Quantity, UOM, Scale Type, Yield Type, Cost Allocation

Entering By-products
Quantity, UOM, Scale Type, Yield Type, By-product Type

Quantity, UOM, Substitution Effective Date, Scale Type, Scale Multiple, Scale Rounding Variance, Rounding Direction, Consumption Type, Contribute to yield, Contribute to Step Quantity, Phantom Type, Buffer, Scrap Factor

Entering Ingredients

Formula Ingredient Release

Select the Appropriate Ingredient Release Method
Choose the release method that fits your requirements to relieve ingredients from inventory. Automatic release of ingredients releases all ingredients when the batch is released. Automatic by step releases ingredients after each step is completed, on a step by step basis. Use manual release for full hands-on control of ingredient release. Or, use an incremental release to keep inventory quantities current by back flushing materials as they are used.

Formula Status Change

Default Formula Status is always New which allows us to change anything in the formula

Formula Statuses
Formula Status is changed as per the use of the formula. -Approved for Laboratory Use, Approved for General Use, Obsolete/Archived

Formula for Production

Approved for Laboratory Use Used in laboratory batches Approved for General Use used in production batches

Formula Statuses
1. New to make changes at any time, assuming you have security access. Default. New is default and we can change it to 2,3,4 statuses

2. Approved for Laboratory Use for use in laboratory batches and cost rollups for the laboratory. 3. Approved for General Use for use in production batches. 4. Obsolete/Archived to specify the object can no longer be used unless the status is changed. 5 & 6 statuses are usually after it is assigned to status 2,3,4 5. On Hold to specify the object cannot be used until the status is changed. 6. Frozen to prevent any further changes to the object and any dependent data.

 Routing is an optional setup in OPM. It is very important and useful in detail study of the process and improvising it through activities and planning and scheduling the Resources to use them in optimum way. A routing is a sequenced set of operations to perform to complete a production batch. The operations are presented in a series of steps that organize these operations into an orderly set of activities that have individual resources associated to them.

Routing

Routing

Step (Operation)

Resource

Activity

Activity
Process Engineer Setup Activities
Activities are the actions performed during the production process and are set up to divide a manufacturing process into logical breakpoints. By analyzing and refining the granularity of activities, businesses can improve their work methods and reduce time to manufacture so that activities performed in operations are completed in the shortest possible time with the least effort to deliver the appropriate level of quality.

Generic Resource
Process Engineer Setup Plant Resources
Resources are assets used for production like Production Equipment & Employee Labor Define all the resources generally (eg. Blenders) or specifically (Blender1, blender 2) Resource class are for grouping the same kind which is optional Cost component class are for costing purpose (kind of cost for the resource)

Process Parameters
Process Parameters are resource parameters that are used to use the resource in safe and optimum level like temperature, speed of the spindle and pressure. We specify the target value, minimum and maximum values with units.

Plant Resource
Process Engineer Setup Plant Resources
A single resource can be used for different purposes in different inventory organizations and this might vary the capacity of the resource from one organization to another. So a resource should be defined at every inventory organization separately and should be enabled to make it available for the scheduling and planning. Resource Information window is used to enter the specific resource information for the inventory organization. Resource information window contains
Costing information Resource usage UOM Capacity Planning availability of resource in each Inventory organization for scheduling and planning. Process parameters can also be defined for specific inventory organizations.

Resource Information
Inventory organization information in the header

Process Operation

Process Engineer Process Operations

Operations are the combination of activities and the resources required for performing them. We can use activity factor to specify the no. of times an activity is performed, this will in fact makes easy to track and data entry of the repeated activities. Can edit the Resource parameters for particular operation.

New Operation
Process Engineer Process Operations

Operation - Activity Resource - Throughput

Resources for every Activity should be defined in an Operation. Resource Process Quantity and UOM are entered in the Resource Information window for every organization we assign. Throughput window lets us override the details for particular operation. Resource process qty is converted to Operation process qty if required.

Operation - Activity Resource

Enter the Component Class code. The component class is set up in the Oracle Process Manufacturing Cost Management application and defaults from the Resource. Cost Analysis Code and Cost Analysis Description for the activity. The code and description default from the activity.

Cost Information

Operation - Activity Resource

- Scheduling Information
Select a Plan Type for the displayed Resource and Description: Select Auxiliary for resources that work as companions with the primary resources to perform an activity in the Operation. This type of resource works with the critical resource when using Advanced Supply Chain Planning (ASCP) and can affect the overall duration of an operation. When using ASCP it is important to keep the throughput rate of this resource to be less than the throughput rate of the primary resource. Select Primary to indicate the rate determining resource. It limits or determines throughput. It is also referred to as the bottleneck or critical resource. There can only be one Primary per resource. Select Secondary for resources that work as companions with the primary resource. The difference between a secondary and auxiliary resources is that when using ASCP, secondary resources are ignored. In ASCP, only the primary and auxiliary resources have functionality. Resources are assigned a Plan Type indicating primary (1), auxiliary (2), or secondary (0) on the Process Operations window. In ASCP, secondary resources are ignored. With OPM Capacity Planning, you have the option of using alternate resources.

Operation - Activity Resource

- Scheduling Information
Enter the Count as the number of resources needed for the activity entered. For example, if two blenders are used for mixing, enter a 2 in the count. Required. Enter the Offset Interval as the time delay from the start of the activity to the point where the resource is actually required. Select the Scale Type. Designate whether scaling is used to determine resource quantity. Scaling is defined as the proportional increase or decrease of resources. For example, setup and cleanup activities are usually not scaled, while manufacturing activities are scaled:
Select Proportional Scaling if the resources change in a ratio to the quantity of material being processed. Select Fixed if the resources do not change, regardless of the quantity of material being processed. Select Fixed By Charge if the resources change as a result of the number of charges specified.

Operation - Activity Resource

- Scheduling Information

Operation Status Change

The statuses are as same as formula

Routing
Process Engineer Routing

Entering & saving Routing

Entering & saving Routing

Class: Routing class should be pre defined Process Quantity: total quantity of material for the routing and is used to scale individual step requirements. Planned Loss Fixed Process Loss, UOM Theoretical Process Loss Enforce Step Dependency: Cannot complete the step before completing the previous step, Step release and completion will be manual in the Recipe of the Routing. Contiguous: Uninterrupted run of the batch. No stop once it is started. Even if it runs into downtime in the calendar. Routing Steps are the operations in the routing with sequence numbering.

Recipe
Process Engineer Recipes

Recipe
Process Engineer Recipes

Entering and saving Recipe

Entering and saving Recipe

Process Loss Factors Enable Better Material Planning Due to factors such as evaporation or changeovers, materials can be lost or unrecoverable in a production step. These lost materials need to be planned for to achieve the targeted process quantity for a step. The loss can vary depending on the material being processed, therefore a production loss factor must be defined at a product operation level, and reflected in production and planning for ingredients associated to the step. Product Development allows entry of a process loss factor to enable better material planning.

Recipe Validity Rules

Entering and saving

Production Supervisor
This is to record the information regarding the production scheduling and actual production through FPO(Firm Planned Order) and Batches FPO:
This is to make schedules for the production depending on the requirement like make to order and stock

Batch
This records the actual production in batches

FPO is converted into one or more batches or we can make a new batch directly.

Production Supervisor Create Document

FPO/Batch Single Recipe Quantity

FPO/ Batch are crated the same way.

FPO/Batch Required Product Quantity

FPO/Batch Recipe Total Output

FPO/Batch Recipe Total Input

FPO Details/Actions

FPO Convert To Batch

FPO Convert To Batch

Option to chose Recipe Validity Rules

A FPO can be converted to multiple batches of different recipes and validity rules. No matter what recipe is selected at the time of creation of FPO, final selection is done at the conversion to batch.(Selection of recipe is mandatory while making FPO)

FPO converted to 3 batches

FPO status
The status of EPO remains as pending till the whole quantity is converted to batches. The remaining quantity will be reflected when you try to convert to batch again. The Planned Qty is the remaining Qty available as per FPO for making the batch.

Converting remaining FPO to batch

Out of 100KG FPO, 3 batches of 25 KG each are made earlier. Since the remaining 25KG reflected.

Converting remaining FPO to batch

The remaining 25KG could had been converted to any number of batches. The converted batches will be in pending status.

Production Supervisor Batch Details

All Batches that are created will have default status as Pending

Batch Details
Batch details form showing the Recipe, Dates, Ingredients, Products, By-Products and their quantities with other parameters.

Releasing a Batch
Releasing a Batch is actually making it available for production. This will change batch status into WIP

Batch Status WIP

Lets you go with material transactions like ingredients consumptions and products generation. Quality control like sample generation and results entry

 Batch Steps are the steps/operations defined in the routing. Batch is made based on a recipe and a recipe is attached to routing.

Batch Steps

Batch Step Actual Dates

Batch Step Step Quantities

Batch Step Charges

Batch Step Others

Material Transaction
This window is used to WIP Issue the ingredients (consume from the inventory) and WIP Complete the Products and By-Products (Generate the Product into inventory).

While issuing an ingredient, we can use this form that displays the availability of the item in the inventory as shown below. Defining picking rules will help in picking the items using pre defined strategies.

Select Available Inventory

Material Exceptions
Once we are done with Select Available Inventory, the Material Exceptions window allows us with proceeding with the transactions with all the details as shown below.

Material Transactions understanding

In process manufacturing real time scenario, material transaction is not always done at a single time and a batch input is not done at a time. The material is consumed in intervals as per the requirement. The material transactions window helps us in transaction of material how much ever required and when ever needed before completion of the batch. The dates and quantity are recorded and can be tracked.

Batch Completion
After all material transactions and completing the steps, when the production is done, the batch is completed. Batch completion ways
Complete from WIP: In this the batch is first released where the start date is mentioned and then while completion the completion date is mentioned. Direct complete: in this the batch is directly changed to status complete. Here we should mention the start and completion dates at a time and the application directly guides us to the material transaction window.

Batch Release

Complete after Release

Direct Complete

Showing the Completed status of the Batch

Quality
Quality: It is conformance to standards or requirements. Standards are set based on the need. Anything that is manufactured or any service that has been delivered posses a need for it. When there is a need there is even a measure of need and the quality is all about how good that need is met. The point is customer is only satisfied when his needs are fulfilled. The quality of a product or service is not just meeting the physical standards but it also depends on the time frame. The needs are to be fulfilled in the way they are needed and the time they are needed. The most important part of quality management is the successful communication of quality requirements from receipt of incoming materials to the shipment of finished goods. OPM Quality Management provides notification and approval workflows to control quality throughout the supply chain. There should be proper sampling plans made to pick the samples at stages of material where they are needed which is error prone due to the complexity of tracking. OPM Quality enables us to make sampling plans attached to specification.

Test

Specification
In quality, the tests, sample plans are defined in general and are not assigned to any organization in particular. There is 1 to 1 mapping for test and test methods. Test Methods can be optionally defined for single organization and Item if required. The purpose of Specification is to ensure the quality conformance of materials, such as an item or a lot, or for environmental conditions, such as a resource or a subinventory locator. The process of quality conformance needs one or more tests to be performed at a time on different samples. So we need to group tests and sampling plans as required either for a item or a resource or a subinventory locator.

Specification
Specification

Monitoring

Item (Item/Lot)

Resource

Locator

Specification - Item

Specification Validity Rules

Validity Rules Summary

Product Samples

Item Sample Window

Results Entry

Sample Status complete

Disposing the Sample