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Oracle Manufacturing SolutionIntegrated
IntelligenceCost
Analysis Productivity
Planning
• Planned Orders• Schedule Changes• Component
Substitutes• Resources
Substitutes
ProductLifecycle
MgmtWarehousing
/ Transportatio
n
Service
AssetMaintenance
• Demand Schedules• Sequencing• Configured Order
Lot / Serial Genealogy Tracking
Quality Management
Discrete Flow
Process Lot-Based
CTOETOMTS
Mixed Mode
• Production Status• Material Availability• Mfg Capacity• Schedules/Changes• Ship Notices• Invoices/Payments
EnterpriseShop Floor
MES APIs,Direct
Access
Customer
PartnerCollaboration
Contract Mfgrs
Real-TimeWIP Visibility
Contract Mfgrs
Model ShopFloor
Suppliers
Suppliers
Analyze AdjustSample
What is Flow Manufacturing?
● More than a module - its a “new way of life”● Dedicated assembly lines supporting product families● Mixed model production - lot size of one● Balanced line ensures smooth flow and optimum
resource utilization● Demand driven line and cell schedules● Pull manufacturing● Point-of-use kanban replenishment
Oracle Flow Manufacturing Solution
1. Plan for Customer Demand (Configured Products)
2. Design for Balanced Operations
3. Schedule and Sequence for Efficiency
4. Communicate and Complete Production
5. Plan for and Execute Kanban Management
Enables you to:
Oracle Flow Manufacturing Solution
1. Plan for Customer Demand (Configured Products)
2. Design for Balanced Operations
3. Schedule and Sequence for Efficiency
4. Communicate and Complete Production
5. Plan for and Execute Kanban Management
Enables you to:
Plan for Customer Demand
● Complete Integration with Oracle Planning Products, Planning Workbench
● Product Family Definition and Planning▪ Model Definition
▪ Option Class with Planning Percent▪Optional Items with Planning Percent
● Two-level Master Scheduling
Techniques used
Production Planning
● Forecasts at family level● Explode family forecasts to members ● OR - plan based on unconsumed family forecast● Consume family forecast with member demand● Check ATP by product family or individual item
Product FamilyLaptops
Envoy Presidential
30%
Envoy Multimedia
50%
Envoy Sentinel
20%
Forecast & Consume
Sales Orders
Oracle Flow Manufacturing Solution
1. Plan for Customer Demand (Configured Products)
2. Design for Balanced Operations
3. Schedule and Sequence for Efficiency
4. Communicate and Complete Production
5. Plan for and Execute Kanban Management
Enables you to:
Seq. Task
Valu
e A
dd?
Setup
Mac
hine
Labo
r
Dyn
amic
/ Sta
tic
Qty
Int\E
xt
Mac
hine
Labo
r (s
ec)
Move Quality Info.
Description
Install Red Capacitor1 0 1 To Chip Dept Ensure snap
to board
Move to Chip Dept2 600 600
Install Yellow Chip3 0 1 To Inspection Right of Red Cap.
Move to Insp/Test4 600 600
Machine Time = 1800 Sec or 30 Min.
Inspect - Test5 1 To FGI Warehouse
Move to FGI Warehouse6 600 600 To Shipping Compare Order to
Product
Labor Time = 1803 Sec or 30.05 Min.Elapsed Time = 1803 Sec or 30.05 Min.
Work Content = 3 Sec!!!
0
Sequence of Events DocumentDesign for Balanced Operations
Design for Balanced Operations
Example Processes, Sequence of Events, & Operations
Welding Assembly Painting
mount surface
s
weld edges
boltmoto
r
sealend
s
attach legs
cleansurfac
e
paintsurfac
e
polishsurfac
e
PROCESSES >
SEQUENCEOF EVENTS >
Production line
Op 10 Op 20
Op 30
Op 40
Op 50
LINE OPERATIONS >
Complex Bill - high maintenance
Flat BOM
Concurrent Process Engineering
Design without considering the factory process
Visual Network Routings
Design for Balanced Operations
Other Objectives
▪ Graphical Line Designer ▪ Network Routings
● Sequence of work events● Network of operations
▪ Alternate Paths▪ Feeder Lines▪ Drag and Drop
How Oracle Supports Them
Design for Balanced Operations
Design for Balanced Operations Graphical Line Designer
Primary, Alternates, Rework, Subassembly Feeder, Etc.
● Mixed Model Map Workbench▪ Analyze Different Scenarios
▪New Product Introduction▪Changes in Demand▪Process Improvement▪Bottleneck Resolution
How Oracle Supports It
Design for Balanced OperationsHow do I balance the line?
Design for Balanced Operations How do I balance the line?
Example Processes, Sequence of Events, & Operations
Welding Assembly Painting
mount surface
s
weld edges
boltmoto
r
sealend
s
attach legs
cleansurfac
e
paintsurfac
e
polishsurfac
e
PROCESSES >
SEQUENCEOF EVENTS >
Production line
Op 10 Op 20
Op 30
Op 40
Op 50
LINE OPERATIONS >
Design for Balanced Operations How do I balance the line?
Mixed Model Map Workbench Bottleneck resolution
Mixed Model Calculations
● Line Takt Time = ((Mts/Day)x No of Dem Days))/Total Demand
● Machines Needed= MC Wtd Time/Opn Takt Time
● MC Assigned=Tot No of MC (In the dept)● Labor Needed= Lbr Wtd Time/Opn Takt
Time● Labor Assigned=Tot Av (In the dept)
Oracle Flow Manufacturing Solution
1. Plan for Customer Demand (Configured Products)
2. Design for Balanced Operations
3. Schedule and Sequence for Efficiency
4. Communicate and Complete Production
5. Plan for and Execute Kanban Management
Enables you to:
Line Scheduling
● Schedule production based on customer orders (or planned orders)
● Sequence production based on model mix to maximize line utilization
● Smooth demand fluctuations using demand fences
● Review material and resource availability for product family schedule
Objectives
Scheduling Algorithms
● No Level Loading– Scheduled by “Scheduling Criteria”– Scheduled until capacity is reached
● Level Daily Rate– Total demand is spread evenly across
scheduling horizon● Mixed Model
– Same as Lvl Daily Rate– Follows a production rule pattern for mix
Sequencing Criteria
● Order Entry Date● Order Priority● Order Promise Date● Order Request Date● Order Scheduled Date
Sales Orders
Planned Orders
Planned Order Due Date
Line Scheduling
● Sequence based on user-defined priorities● Schedule to line rates● Balance production lines● Schedule mixed-model production● Execute directly from sales order demand
Line Scheduling Workbench
Line SchedulingSales Order Demand
Product B Product B Product BProduct A Product A Product A Product A
SO 1
1-JUN
Priority 2
SO 2
2-JUN
Priority 1
SO 4
4-JUN
Priority 2
SO 5
5-JUN
Priority 1
SO 3
3-JUN
Priority 3
Algorithm = No Level Load, Criteria = Order Priority, Date
1-JUN 2-JUN 3-JUN 4-JUN Unscheduled
Line Scheduling
SO 1SO 2 SO 4
SO 4SO 5 SO 3 SO 3SO 1
Line Capacity
● Schedule only 4 days of production
Algorithm = Level Daily Rate (Spread Demand Evenly)
1-JUN 2-JUN 3-JUN 4-JUN Unscheduled
Line Scheduling
Line Capacity
Product A
Product B
Product A
Product B
Product A
Product B
Product A
Product B
● Same criteria options to sequence orders
Algorithm = Mixed Model Scheduling (Production Rule Pattern)
1-JUN 2-JUN 3-JUN 4-JUN Unscheduled
Line Scheduling
Line Capacity
● Sequence Based on User-Defined Priorities● Execute Directly From Sales Order Demand● Schedule Mixed-Model Production● Balance Production Lines● Feeder Line Synchronization● Supplier Synchronization● What Ifs and Simulations
Techniques Used
Schedule and Sequence for Efficiency
Oracle Flow Manufacturing Solution
1. Plan for Customer Demand (Configured Products)
2. Design for Balanced Operations
3. Schedule and Sequence for Efficiency
4. Communicate and Complete Production
5. Plan for and Execute Kanban Management
Enables you to:
● Define Pull Sequences
● Calculate #of Cards / Kanban Size
● Kanban Requirements Simulation
● Generate Non-Replenishable Kanbans
● Automate Transactions - Generate Requisitions
Techniques used
Plan for and Execute Kanban Management
Pull Sequences
Production line
Op 10 Op 20
Op 30
Op 40
Op 50
raw in processloc 1 loc
5loc 4
loc 2
supplier s1 line l1
intra-org r1
inter-org i1
raw in processloc
3
supplier s2
supplier s3
item A
item B
item A
item C
item D
item D
Plan for and Execute Kanban Management
● Replenish Internal Kanbans
– Stores Move (Intra-Org)– Production
● Replenish External Kanbans– Supplier Kanbans
● Aggregate Kanban Signals– Move Order (Inter-Org)
● Non-replenishable Kanbans
Kanban Execution Signals
Plan for and Execute Kanban Management
52
Supplier Kanban ExecutionPurchase to Build – Component demand and Production Sequence communicated to suppliers.
Oracle Flow Manufacturing Solution
1. Plan for Customer Demand (Configured Products)
2. Design for Balanced Operations
3. Schedule and Sequence for Efficiency
4. Communicate and Complete Production
5. Plan for and Execute Kanban Management
Enables you to:
● Flow Workstation▪ Communicate Schedule▪ Convey Work Instructions (OMS)
● Work Orderless Completion▪ Extremely Lightweight Entity▪ No Pre-exploded Bills and Routings▪ Substitutions and Changes▪ Management of Engineering Changes▪ Serial / Lot Control, FG and Components
● Scrap Reporting● Quality Collection Integration
Techniques Used
Communicate and Complete Production
Flow WorkstationPaperless Communication of Production Schedule - work instructions, OMS, components, resources
Flow WorkstationPaperless Communication of Production Schedule - work instructions, OMS, components, resources
Flow WorkstationPaperless Communication of Production Schedule - work instructions, OMS, components, resources
Flow WorkstationPaperless Communication of Production Schedule - work instructions, OMS, components, resources
Attachments
Work Order Less Completion
No Pre-exploded Bills and Routings, Management of Engineering Changes, Substitutions and Changes, Serial / Lot Control, FG and Components, Scrap,
Quality Integration, Mobile Support
Oracle Flow Manufacturing
● Complete Flow Infrastructure– Flow and ERP Data Model Integration– Demand Management– Line Design and Balancing– Line Scheduling– Production Execution– Kanban Planning and Execution
Recommended