Enhancing Shop Floor Quality Processes in a Continuous ... · PDF fileProcesses in a Continuous Manufacturing Environment ... about Oracle SCM and ASCP modules. ... Oracle Apps implementations

Enhancing Shop Floor Quality Processes in a Continuous Manufacturing EnvironmentHari Krishnan Subramanian / Bhavesh Panchal02 November 2012

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About the Speaker

Bhavesh PanchalManager, Oracle Package Technologies,Deloitte Consulting India Ltd.Email - [email protected]

Bhavesh is an Technology advisor inOracle space having 14+ years ofTechno Functional experience.Experienced in leading large, complexand global projects in IT Consulting,Information System Management,Manufacturing and Finance industry.Over 12 years in technologyconsulting, assisting clients achievebusiness goals throughimplementation of Oracle ApplicationsE-business solution and customapplications. He has Strong knowledgeabout Oracle SCM and ASCP modules.He has extensive experience inimplementing EBS in Consumer &Industrial Product and Technology andMedia industries

Hari Krishnan SSenior Consultant, Oracle Package Technologies,Deloitte Consulting India Ltd.Email - [email protected]

Hari is an Oracle practitioner having 8+years of Functional experience inOracle Apps implementations &Business application fields,Manufacturing Technology &Production planning. He has worked inmultiple implementations, Support,Upgrade and Product Developmentprojects. Oracle certified ASCP & R12BFA functional consultant with goodfunctional knowledge across allMFG/SCM modules. He has strongknowledge on the Oracle VCP modules.He has extensive experience inimplementing EBS in C&IP, TMT &Health Sciences industries. He is also aDeloitte certified Lean Six Sigma YellowBelt and SCT Level 1 functionalconsultant with excellent clientinteraction, team participation anddelivery skills

mailto:[email protected]

mailto:[email protected]

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Deloitte’s Global Footprint

• Deloitte has a globally connected network of member firms in more than 150 countries• Deloitte comprises of more than 193,000 professionals around the world

Global Revenues: US $31.3 Billion

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Deloitte U.S. India Offices

• Commenced operations in 2000, and has grown to emerge as a global competency center for high-quality services

• Deloitte U.S. in India has ~ 15,000 employees

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Introduction

Business Driver

Business Challenges

Leading Practices in this area

Common Design Considerations

Process Specific Design Considerations

Process Flow

Standard Oracle MES & Quality Collection Process

Solution Overview & Process Description

Benefits of the solution

Lessons Learnt

Agenda

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Introduction

Business Driver

Business Challenges




Process Flow




Lessons Learnt

Agenda

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Introduction

The crux of operational efficiency reporting in a continuous manufacturingenvironment revolves around three main components: Timely capture of qualityresults, choice of analysis techniques and reports with meaningful interpretations.However, this reporting is incomplete unless the final output is suitablyrepresented in a tabular/graphical form thereby resulting in corrective actions andquality improvement.

This presentation describes an end-to-end quality process, which leverages thecapabilities of Oracle Quality & Oracle Manufacturing Execution System (MES)modules, for a leading packaging industry client which operates on a continuousmanufacturing model. This document also covers the business challenges /requirements that a client in this industry has, leading practices that wereimplemented, design considerations & solutions that were designed & developedto successfully overcome these challenges/ requirements..

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Introduction

Business Driver

Business Challenges




Process Flow




Lessons Learnt

Agenda

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Business Driver

In a growing competitive world, data accuracy in Supply chain network is of high importance for companies to increase their operating efficiency. Quality system is one of the integral part of the companies’ software system and in most of the companies, quality system used is a standalone database. For example: associating receiving transactions with Supplier Management data would be cumbersome.

Supplier

Manufacturer

Distributor

Customer

Quality System -1

Quality System -2

Quality System -3

Quality System -4

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Introduction

Business Driver

Business Challenges




Process Flow




Lessons Learnt

Agenda

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Business Challenges

§ No standardized processes to capture quality results. Multiple applications usedacross divisions / organizations to capture quality results

§ Time based quality system

§ Lack of pre-defined and integrated end-to-end process availability for quality

§ No reporting and charting capabilities in the existing applications for qualitydata analysis

§ Divisions / o rganizations within the company have different Certificate OfAnalysis (COA) / Certificate Of Conformance (COC) templates andrequirements

§ Tedious manual processes for generating COA & COC reports

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Introduction

Business Driver

Business Challenges




Process Flow




Lessons Learnt

Agenda

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Leading Practices In This Area

§ Single integrated application to capture quality results across the company

§ Align to statistical process control processes and aim for zero defects

§ Standardized use of reports & charts (Control, Histogram, Trend & Paretocharts) to analyze quality results

§ Align the reporting strategy to the corporate strategy and design the COA & COCto meet the reporting strategy. (i.e., “work backwards” from reporting needs)

§ Evaluate and automate reporting requirements and eliminate the time spent forpreparing repetitive reports

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Introduction

Business Driver

Business Challenges




Process Flow




Lessons Learnt

Agenda

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§ Global design should be flexible; taking into account the different requirementsof the divisions / organizations previously identified to prevent any constraintsduring future roll-outs

§ Maximize the use of standard functionalities. Minimal customizations in theapplication as far as possible

§ Make quality data collection, analysis & reporting processes as simple aspossible and user friendly

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Introduction

Business Driver

Business Challenges




Process Flow




Lessons Learnt

Agenda

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§ Minimum key strokes for entering quality results. More the key strokes; higher isthe risk of keying errors. Single GUI for the operator to enter production & qualitydata. Quality collection plans invoked in a click of a button

§ Quality data collection specific to the type of product being manufactured

§ Time based quality data collection process (not transaction based)

§ Ease of data retrieval

§ Quality charts generated with ease

§ Automated generation and transmission of COA / COC reports

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Introduction

Business Driver

Business Challenges




Process Flow




Lessons Learnt

Agenda

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Process Flow

Notification

Supplier Data

Production

Field service failure

Col

lect

ion

Plan

e-documents

Reports

Online enquires

Charts

QualityData

Repository

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Introduction

Business Driver

Business Challenges




Process Flow




Lessons Learnt

Agenda

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Select the Discrete Job In Oracle MES

Standard Oracle Manufacturing Execution System (MES) &Quality Collection Process

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Perform Move Transaction In MES

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Capture Quality Results

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Save the transaction

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Introduction

Business Driver

Business Challenges




Process Flow




Lessons Learnt

Agenda

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Process Description

Quality Data Collection Process made easy

§ Items were grouped by the quality process that they pass through (categories)§ Separate collections plans were defined for each quality process§ An extension was built and a new button was added in Oracle MES (Manufacturing Execution

System) GUI for linking the quality processes (New functionality. Not available in seeded product)§ Quality results data collection process gets invoked through a single button stroke (New

functionality. Not available in seeded product)§ Operator selects the job for which he is performing the quality checks and clicks the quality button

(New functionality. Not available in seeded product)§ Extension checks the quality category they belong to and invokes the associated quality collection

plan (New functionality. Not available in seeded product)§ All reference information such as Job, Item, Item Description, Inspection type (First Piece, In

Process or Last Piece) pre-populated for the operator (New functionality. Not available in seeded product)§ Validations were built to check if the operator is using the right spindle in the machine (New

functionality. Not available in seeded product)§ Operator performs the physical quality checks, enters the quality results in the GUI and saves the

information§ Capabilities to record the crew who worked on the manufacturing line was built. This process also

gets invoked through a single button stroke (New functionality. Not available in seeded product)§ Capabilities to record the quality results during line startup were built. This process also gets

invoked through a single button stroke (New functionality. Not available in seeded product)

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Process Description (Cont.)

Quality data analysis made easy:

§ Capabilities built for the Quality supervisor to select a collection plan and chart the quality results for all the collection elements in one go (New functionality. Not available in seeded product)

§ Consolidated charts for analyzing manufacturing line performance (New functionality. Not available in seeded product)

Quality data reporting made easy:

§ Standardized COA & COC templates and design was built that can be used across divisions / organizations

§ Master Collection plan created to store the customer requirements§ COA / COC reports auto generated during the shipping process. Report

looks at the quality data stored in the application for that product / product setup group and pulls the data into a pre-defined report format. COA / COC report gets emailed to the customers automatically (New functionality. Not available in seeded product)

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Process Description (Cont.)

Functional & Technical design made easy:

§ Complete extension is functional setup driven§ Best practices of personalization and extensions were used. We leveraged

seeded functionalities to achieve end goals§ Seeded functionalities retained§ OAF & ADF technologies used to build the extension, charts & reports§ Application navigation made easy. Quality data collection, analysis &

reporting invoked in max one or two mouse clicks§ Both technical & functional design and solution is upgrade safe§ Reports have been designed to use Global temporary tables to handle

critical performance issues. Report execution time, for even the most complex reports, is less than15 seconds

§ Code modularity concepts, explain plan & trace file analysis tools were used to handle and optimize performance requirements

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Oracle – MES Dispatch List

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Oracle – Quality Charts - Histogram

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Oracle – Quality Charts – Trend Chart

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Oracle – COA

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Introduction

Business Driver

Business Challenges




Process Flow




Lessons Learnt

Agenda

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Benefits of the Solution

§ Single integrated application across divisions / organizations

§ Single GUI for the operator to report production and for capturing quality results

§ Standard time based quality results capturing application

§ Standardized process across Divisions & organizations

§ Streamline the entry of capturing quality results

§ Effective Reporting

§ Standardized charts (format & data used in charts) used across divisions &organizations

§ Automated COA report generation and transmission to customers

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Introduction

Business Driver

Business Challenges




Process Flow




Lessons Learnt

Agenda

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Lessons Learned

§ Oracle Quality is best utilized as a data collection solution and not a quality analysis tool (e.g. Minitab)– Oracle will perform some basic calculations in the seeded charts and graphs,

but the functionality is very limited.§ Oracle Applications Framework (OAF) personalizations will be your best friend

– Navigating the Oracle Quality is not the easiest task, so OAG personalizations can be leveraged to streamline data entry for shop floor personnel.

§ Tying the Collection plans to category of items makes the solution simple. Create & use ‘Quality categories’ to associate items to collection plans§ Keep the collection plan actions simple

– More complex the collection plan actions are, more complex becomes solution design

§ Design & develop basic charts required for quality data analysis (Trend Charts & Histogram)

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As used in this document, "Deloitte" means Deloitte Consulting LLP, a subsidiary of Deloitte LLP. Please see www.deloitte.com/us/about for a detailed description of the legal structure of Deloitte LLP and its subsidiaries. Certain services may not be available to attest clients under the rules and regulations of public accounting.

This publication contains general information only and is based on the experiences and research of Deloitte practitioners. Deloitte is not, by means of this publication, rendering business, financial, investment, or other professional advice or services. This publication is not a substitute for such professional advice or services, nor should it be used as a basis for any decision or action that may affect your business. Before making any decision or taking any action that may affect your business, you should consult a qualified professional advisor. Deloitte, its affiliates, and related entities shall not be responsible for any loss sustained by any person who relies on this publication.

Copyright © 2012 Deloitte Development LLC. All rights reserved.Member of Deloitte Touche Tohmatsu Limited

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Documents

Enhancing Shop Floor Quality Processes in a Continuous ... · PDF fileProcesses in a Continuous Manufacturing Environment ... about Oracle SCM and ASCP modules. ... Oracle Apps implementations