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Training On Training On Oracle Work In Process 11i Oracle Work In Process 11i Oracle Applications 11i A Presentation by EAS – Oracle Applications September 2003

Oracle WIP

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Page 1: Oracle WIP

Training OnTraining OnOracle Work In Process 11iOracle Work In Process 11i

Oracle Applications 11i

A Presentation by EAS – Oracle Applications

September 2003

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AgendaAgenda

Introduction to Work In Process Overview of Work In Progress Setting Up & Implementing WIP Create and Update Discrete Jobs Scheduling Discrete jobs Create and Update Repetitive Schedules Scheduling Repetitive production Work in Process Transactions - Moves and Resources Complete Discrete Jobs and Repetitive Schedules Work In Process Interfaces

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Oracle Work In Process is a complete production management system.

Work In Process supports discrete, project, repetitive, assemble-to-order, and work order-less manufacturing.

Inquiries and reports give a complete picture of transactions, materials, resources, costs and job/schedule progress on the shop floor.

Introduction to Work in Process

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Production Methods –Discrete

Discrete production records all production activities against a discrete job. It represents a plan to produce a specific quantity of an item on a specific date. All material issues (Manual and Backflush), and all resource charges (Automatic and Manual) are charged to a specific jobDiscrete job can produce Assemble to Order (ATO) items and Configure to Order (CTO) item.

Introduction to Work in Process

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Production Methods –Repetitive

Repetitive production models high-volume production of standard items over a period of time. Production is recorded against a repetitive schedule that represents a plan to produce an item at a given daily rate for a period of time.

Introduction to Work in Process

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Overview of Work inProcess

Following types of jobs and schedules can be used to support specific manufacturing needs:

Standard and Non-Standard Discrete Jobs Standard and Non-Standard Project Jobs Repetitive Schedules by Production Line/Assembly Final Assembly Orders Work order less completions

Overview of Manufacturing Support

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Overvi ew of Wo rk inPr ocess

Oracle Work In Process can be used to schedule production resources and materials, to meet customer delivery requirements and to maintain a smooth production flow.

Scheduling establishes expected dates and times for material and resource requirements, as well as for the supply availability of assemblies built on the jobs and repetitive schedules.

Overview of Production Scheduling

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Overvi ew of Wo rk inPr ocess

Production Scheduling includes: Loading/sequencing repetitive production by

assembly/production line. Scheduling start / stop times for jobs, operations and

resources to the minute. Scheduling fixed, variable and overlapping time elements. Forward, backward, manual and midpoint forward

rescheduling. Automatically updating the master schedule.

Overview of Production Scheduling (Cntd..)

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Overvi ew of Wo rk inPr ocess

Work In Process uses two scheduling methods: Detailed Scheduling Repetitive Line Scheduling

Note: Oracle Work In Process only provides unconstrained scheduling.

Overview of Production Scheduling (Cntd..)

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Overvi ew of Wo rk inPr ocess

Oracle Work In Process gives the ability to control and monitor the materials used for production and to view how they flow from inventory to discrete jobs/schedules, and from the discrete jobs/schedules to inventory.

Material transactions: Issue and Return Material to Inventory Back flush Material Replenish Material

Overview of Material Control

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Overvi ew of Wo rk inPr ocess

While defining jobs and repetitive schedules,

Material can be controlled by: Combining bills of material with routings to create specific

material requirements. Specifying when and where materials are to be

issued or back flushed. Assigning Supply Types to control how materials are

supplied.

Overview of Material Control (Cntd.)

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Overvi ew of Wo rk inPr ocess

Shop floor control helps manage the flow of production in a plant leading to efficiencies that can lower costs and help to meet the delivery commitments.

Shop floor control options: Move assemblies within operations. Load move transaction information from external systems. Define and assign shop floor statuses. Auto-create purchase requisitions for outside processing

operations . Rework problem assemblies. Scrap assemblies.

Overview of Shop Floor Control

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Overvi ew of Wo rk inPr ocess

There are five available intra-operation steps. Queue: Default intra-operation step for every operation in a

routing Run: Assemblies which are ready to be worked on. To Move: Assemblies waiting to be picked up for next

operation. Reject: Rejected Assemblies Scrap: Scrapped Assemblies

Overview of Shop Floor Control (Cntd.)

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Overvi ew of Wo rk inPr ocess

Oracle Work In Process considers an assembly to have completed an operation if the assembly is at To Move, Reject, or Scrap steps.

Oracle Work In Process considers an assembly to have not completed an operation if the assembly is at Queue or Run steps.

Overview of Shop Floor Control (Cntd.)

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Overvi ew of Wo rk inPr ocess

A resource can be assigned to each operation on a Work In Process routing.

A resource can be assigned manually, after creating a job or can be added to the operation while creating the routing.

A resource resides within an operation, it can be a person, a machine, tools, services, etc.

There are three resource charge types:-WIP Move-Manual-PO Move/PO Receipt

Overview of Resource Tracking

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Overvi ew of Wo rk inPr ocess

Import transactions enables users to: Access real time and accurate information to increase

efficiency through out the fulfillment process.

Key technology enablers

– Mobile Computing & Process Critical devices

– Wireless Networks

– Bar code Technology

Overview of Importing Transactions

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Overvi ew of Wo rk inPr ocess

Use WIP accounting classes to establish valuation and variance accounts.

Use Standard, Average or LIFO/FIFO costing. Cost standard and non-standard asset discrete production

by job. Cost jobs by project in Oracle Project Manufacturing

Costing. Cost and report repetitive and non-standard expense

production by period.

Overview of Work In Process Costing

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Overvi ew of Wo rk inPr ocess

Charge and report resource, outside processing, and overhead costs by activity.

Track repetitive production costs by assembly on a line/ individual repetitive schedule.

Track and report costs through the various stages of production.

Period close costs are calculated when an accounting period is closed.

Overview of Work In Process Costing (Cntd.)

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Setting Up & Implementing WIP

1.Define WIP parameters (Req.)

2.Define WIP Accounting Classes (Req.)

4.Define Production Lines (Optional)

3.Set WIP Profile Options (Req.)

WIP Set up

5.Define Repetitive assembly (Optional)

B

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Setting Up & Implementing WIP

6.Define Schedule Groups (Optional)

7. Define Employees (Optional)

9. Define Shop Floor Statuses (Optional)

8.Define Employee Labor Rates (Opt.)

10.Define Job/Schedule Docs (Optional)

C

A

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Setting Up & Implementing WIP

11.Define Operation Documents (Optional)

C

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Setting Up & Implementing WIPWIP Parameters

WIP parameters define modes of operation and default values that affect Work in Process WIP parameters can be used to define modes of operation and assign default values for variouswork in process functions.

Only one set of WIP parameters can be defined per organization.

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Setting Up & Implementing WIPWIP Parameters – Screen shots

(N) WIP > Set up > parameters

Determines which accounting class is used as the defaultif category default WIP accounting classes are not set up. Used to default inStandard/non-standard Discrete jobs & Work order-less completions

Determines how lot numbers are

assigned to discrete jobs. Options are job name & based on inventory rules

Determines whether the WIP jobs respond to Sales order changes

.Options are Always/never /When linked 1 to 1 (ATO)

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Setting Up & Implementing WIP

WIP Parameters – Screen shotsDetermines how resource costs are determined as assemblies are completed from jobs into inventory. System Calculated : resources can be costed at either the actual resource costs or at resourcepredefined cost depending on the System Option parameter . For assemblies from a non standard job with no routing, the resource rate from the Average Rates cost type is used.User Defined: you must choose a user–defined cost type using the Cost Type Parameter. This costtype is then used to determine the resource cost for the assemblies being completed.

Used only when ‘system calculated’ option is selected.Use Actual Resources: Resources costs are determined based on the actual costs charged to the job.Use Predefined Resources: Resources costs are determined using the predefined resource cost.

Determines whether the Final Completion in the Completion Transaction window defaults to checked

Applicable only for average costing organizations

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Setting Up & Implementing WIP

WIP Parameters – Screen shotsDetermines which repetitive schedule variances are posted to the general ledger when an accounting period is closed.

Determines the time period within which the system automatically

releases the next Unreleased schedule.

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Setting Up & Implementing WIP

WIP Parameters – Screen shots Determines whether a scrap account is required when you use the Move Transactions window to move job and repetitive assemblies into and out of the Scrap intra-operation step of an operation. also determines how scrap transactions are processed.

Determines whether you can or cannot add an operation to a discrete

job work in process routing during a move

transaction.

Determines whether moves are disallowed if an intra-operation step

that disallows moves exists at an auto charge operation and

Intra-operation step between the From and To operations or at

intervening intra-operation step at the From and To operations if they

are direct charge.

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Setting Up & Implementing WIP

WIP Parameters – Screen shotsDetermines which supply subinventory and, if required by the subinventory, locator are used when back flushing Operation Pull and Assembly Pull components that do not have defaults defined at the bill of material/item level

Determines how lot controlled Assembly Pull and Component Pull component items are selected during back-flush transactions. Not used for lot/serial controlled items

Determines how lots that are automatically selected, based on

whetherthe Lot Selection Method

parameter is set to Receipt Date or Expiration

Date, are verified during back-flush transactions.

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Setting Up & Implementing WIP

WIP Parameters – Screen shots

Determines which intra-operation steps are enabled in WIP routing operations. The options are Queue, Run, To Move, Reject and Scrap. The Queue intra-operation step is automatically enabled for all operations and cannot be disabled. The To Move intra-operation step, even if disabled here, is automatically enabled for the final operations in routings so that assemblies can be completed into inventory.

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Setting Up & Implementing WIP

WIP Parameters – Screen shotsDetermines which shop floor status is assigned to the Queue intra-operation step of an outside processing operation when you create discrete jobs and repetitive schedules. This status ensures that assembly moves from an outside processing resource operation can only be launched by the receipt of a purchase order in Oracle Purchasing.

Determines whether purchase requisitions are created for outsideprocessing operations automatically or manually, and when in themanufacturing process they are created

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Setting Up & Implementing WIPWIP Accounting Classes

Accounting classes are assigned when jobs are defined and when repetitive assemblies areassociated with production lines.Any number of WIP Accounting Classes can be defined and updated.The valuation and variance accounts that are associated with these accounting classes determine which accounts are charged.

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Setting Up & Implementing WIP

WIP Accounting Classes – Screen shots(N) WIP > Set up > WIP accounting classes

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Setting Up & Implementing WIPWIP Accounting Classes

Standard Discrete Accounting Class

An accounting class must be assigned to everydiscrete job, schedule and work order-less completion

Accounting classes can be defined for each type of discrete production used:– Standard Discrete– Asset Non-Standard Discrete– Expense Non-Standard Discrete– Flow Manufacturing

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Setting Up & Implementing WIPWIP Accounting Classes

Expense Non-Standard Discrete Accounting Class

Non-Standard Discrete Accounting classes can be used to group and report various types of non-standard production costs. Example: To track recurring expenses -- machine maintenance or projects with non-standard jobs.The valuation accounts carry the costs incurred on these expense jobs as an asset during the period and automatically write them off to variance accounts at period close.

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Setting Up & Implementing WIPWIP Accounting Classes

Asset Non-Standard Discrete Accounting Class

If non-standard discrete jobs are used to track production costs as assets, an accounting class with a type of asset non-standard can be assigned .

Asset non-standard discrete jobs are costed the same as standard discrete jobs.

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Setting Up & Implementing WIPWIP Accounting Classes

Repetitive Accounting Class

These are used to group production costs and must be assigned to each repetitive line/assembly association that is created. Every schedule for that assembly on that line uses these accounts.

Repetitive manufacturing costs can be analyzed by assembly regardless of the line on which it was manufactured by using the same accounting class for all lines that build that assembly.

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Setting Up & Implementing WIPWIP Accounting Class -Accounts

Material Valuation Account

This is an asset account and tracks material costs.

Under Standard Costing, it is debited at std cost at material issue to a job/schedule and credited when assemblies are completed, close a job/accounting period.

Under Average Costing, this account is debited at the average cost at the time of issue transaction and is credited at assembly completion.

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Setting Up & Implementing WIPWIP Accounting Class

Material Overhead Valuation Account

This tracks material overhead costs.

Under Std Costing, it is debited at std cost at material issue with a overhead to a job. Under average costing, this account is debited at the average cost at the time of the issue transaction.

When assemblies are completed and material overhead is earned, the material overhead account for the completion sub-inventory is debited.

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Setting Up & Implementing WIPWIP Accounting Class

Resource Valuation AccountThis tracks resource costs.

Under Standard Costing, it is debited at std cost when resources are charged to a job/schedule and credited on completion of assembly.

Under Average Costing, this account is debited and credited at the resource rate at the time the resource is charged.

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Setting Up & Implementing WIPWIP Accounting Class

Outside Processing Valuation AccountThis tracks outside processing costs.

Under Standard Costing, it is debited at standard or PO cost when items are received for a job/schedule and credited at standard cost on completion of assembly.

Under Average Costing, the behavior is the same as in Standard Costing.

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Setting Up & Implementing WIPWIP Accounting Class

Overhead Valuation Account

This is an asset account and tracks resource or department overhead cost.

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Setting Up & Implementing WIPWIP Accounting Class

Material Variance Account

This account tracks variances that occur when the previous level material costs charged to the job or schedule do not equal the previous level material costs that are relieved. This calculation gives you a net material usage and configuration variance.

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Setting Up & Implementing WIPWIP Accounting Class

Resource Variance Account

This account tracks variances that occur when the this level resource costs charged to the job or schedule do not equal the this level resource costs that are relieved.

Outside Processing Variance Account

This account tracks the variances that are occur when the outside processing costs charged to the job or schedule do not equal the outside processing costs that are relieved.

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Setting Up & Implementing WIPWIP Accounting Class

Overhead Variance AccountThis account tracks the variances that are occur when the overhead costs charged to the job or schedule do not equal the overhead costs relieved from the job or schedule.

Standard Cost Variance AccountApplies only to Standard Discrete and Asset Non-Standard. It’s charged for the sum of all the elemental standard cost adjustments when standard cost update impacts an active job. Cost updates are not performed for repetitive schedules or expense non–standard jobs.

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Setting Up & Implementing WIPWIP Accounting Class

Expense Variance Account

Normally an expense account, this account is debited and credited when issuing and completing non–standard expense jobs under both standard and average costing.

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Setting Up & Implementing WIP

Shop Floor Statuses

Move transactions are controlled by assigning Shop Floor Statuses to intra-operation steps on the work in process routing. For example a “Hold for Quality Check” status can be assigned to an intra-operation step before moving to the next assembly step.

Shop Floor Statuses can be assigned to any Intra operation step associated with a job/repetitive line/assembly.

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Setting Up & Implementing WIP

Shop Floor Statuses

(N) WIP > Move Transactions > Shop Floor Statuses > Shop floor status

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Setting Up & Implementing WIP

Schedule Groups

Flow schedules and discrete jobs can be assigned to the schedule groups defined.Jobs and flow schedules within a given schedulegroup can be sequenced.Sequencing jobs and flow schedules within a schedule group makes it possible to prioritize, for example, by customer.Schedule groups can be updated.Schedule groups that are assigned to jobs and flow schedules cannot be deleted.

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Setting Up & Implementing WIP

Schedule Groups

(N) WIP > Setup > Schedule Group Screen shots

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Setting Up & Implementing WIP

Labor Rates

Used for defining hourly labor raters to reflect the actual labor rates. The effective date of the hourly labor rates can be added, deleted, and updated for person-type resources (employees).Multiple hourly labor rates can be defined for thesame employee, as long as each rate has adifferent effective date.

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Setting Up & Implementing WIP

Labor Rates

(N) WIP > Setup > Employees > Labor Rates

Screen shots

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Setting Up & Implementing WIP

Production Lines

A production line describes a unique set ofoperations, departments, and/or manufacturingcells that produce one or more of products.

Production lines can be associated with repetitiveassemblies, discrete jobs, flow routings, schedules, and work order-less completions.

Production lines can be defined and updated but cannot be deleted.

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Setting Up & Implementing WIP

Production Lines

(N) WIP > Setup > Production Lines

Screen shots

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Setting Up & Implementing WIP

Operation Documents

Operation Documents can be defined for discretejobs, repetitive schedules, and job/schedule operations.

Operation Documents can then be attached todiscrete jobs, repetitive schedules, and operationsas required.

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Setting Up & Implementing WIP

Operation Documents

(N) Oracle Work in Process > Set Up > Defining Operation Documents

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Setting Up & Implementing WIP

Profile Options

TP:WIP: Background Shop Floor Material Processing:

Used only when the TP: Move Transaction profile is set to Background processing & for a move completion/move return /operation pull back-flush transaction.Available Values:Background Processing: Periodic Processing Concurrent Processing: Inventory Transaction processor is launched.Online Processing (Default): Move transaction processorprocesses the shop floor material back-flush transactions online by calling the inventory material transaction processor.

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Setting Up & Implementing WIP

Profile OptionsTP:WIP: Completion Material Processing

Controls material processing of assembly completion,assembly return, and assembly completion back-flush transactions initiated using the Completion Transactions windowAvailable Values:Background Processing, Concurrent Processing & Online Processing (Default)Note: If TP:WIP: Completion Transactions Form profile is set toBackground processing, this profile is not used. Also, if TP:INV: Transaction Processing Mode profile is set to Form level processing in average costing scenario , this profile must be set to Online for sequential transaction procession.

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Setting Up & Implementing WIP

Profile OptionsTP:WIP: Completion Transaction Form

Determines whether completion transactions are processedonline or in the background when transacting assembly completions using the Completion Transactions window.Available Values:Background Processing, Online Processing (Default)

Note: Also, if TP:INV: Transaction Processing Mode profile is set to Form level processing in average costing scenario , this profile must be set to Online for sequential transaction procession.

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Setting Up & Implementing WIP

Profile OptionsTP:WIP: Completion Transactions first field

Determines which field the cursor defaults to when you firstenter the Completion Transactions window. Set this option based on your predominant manufacturing environment

Available Values:Line, Assembly, Job (Default) , or Sales Order.

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Setting Up & Implementing WIP

Profile Options

TP:WIP: Concurrent Message Level

Determines the level of detail reported in the move transactionconcurrent log file during move transaction validation and processing.

Available Values:-Message level 0 (Default) : Reports errors only.-Message level 1 : Reports processing activities and errors.-Message level 2 : Reports and time stamps processing activities and errors.

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Setting Up & Implementing WIP

Profile Options

TP:WIP: Material Transaction Form

Controls the processing of component issue and return transactions entered in the WIP Material Transactions window.

Available Values:Background Processing, Concurrent Processing & Online Processing (Default)

Note: Also, if TP:INV: Transaction Processing Mode profile is set to Form level processing in average costing scenario , this profile must be set to Online for sequential transaction procession

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Setting Up & Implementing WIP

Profile Options

TP:WIP: Material Transactions First Field

Determines which field the cursor defaults to when you firstenter the WIP Material Transactions window. Set this option based on your predominant manufacturing environment

Available Values:Line, Assembly, Job (Default) , or Sales Order.

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Setting Up & Implementing WIP

Profile options

TP:WIP: Move Transactions: Determines How move transactions performed using the Move Transactions form Available values - Background processing: Processed on a periodic basis-(Default) Online processing: The transaction is processed while saving and control is returned once transaction processing is done.Note: Also, if TP:INV: Transaction Processing Mode profile is set to Form level processing in average costing scenario , this profile must be set to Online for sequential transaction procession.

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Setting Up & Implementing WIP

Profile Options

TP:WIP: Move Transactions First Field

Determines which field the cursor defaults to when you firstenter the WIP move Transactions window. Set this option based on your predominant manufacturing environment

Available Values:Line, Assembly, Job (Default) , or Sales Order.

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Setting Up & Implementing WIP

Profile OptionsTP:WIP: Move Transaction Quantity Default

Indicates if and how move transaction quantities are defaulted.

Available Values:None: No transaction quantity is defaulted.Minimum Transfer Quantity: Transaction quantity defaults if the minimum transfer quantity is less than or equal to the available quantity. If the minimum transfer quantity is more than the available quantity then the available quantity is defaultedAvailable Quantity: If the available quantity is not zero, the transaction quantity defaults to the available quantity..

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Setting Up & Implementing WIP

Profile OptionsTP:WIP: Operation Back flush Setup

Controls the back-flush setup used in the Move TransactionsWindow. It also determines how component lot numbers arederived.

Available Values:-Background processing: Use this option only when lot

numbers are automatically assigned.-Online processing: Use this option when lot/serial numbers

must be manually assigned

.

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Setting Up & Implementing WIP

Profile OptionsTP:WIP: Shop Floor Material Processing

Controls processing of operation and assembly pull back-flush,assembly scrap, move completion, and move return transactions from the Move Transactions window.

Available Values:-Background processing: Use this option only when lot

numbers are automatically assigned.-Concurrent processing:-Online processing: Use this option when lot/serial numbers

must be manually assigned

.

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Setting Up & Implementing WIP

Profile OptionsTP:WIP: Work Order-less Default Completion

Determines the default for the Scheduled flag in the WorkOrder–less Completions window.

Available Values:-Scheduled : The Schedule flag defaults to checked. Use

this option if most of the work order–less completions are based upon flow schedules.

-(Default) Unscheduled : The Scheduled flag defaults to unchecked. Use this option if most of the work order–less completions are manually entered .

.

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Setting Up & Implementing WIP

Profile OptionsWIP: Default Job Start DateDetermines whether the start dates for jobs default to thecurrent date and time or not at all when defining jobs in the Discrete Jobswindow. Available Values are Yes or No (Default)

WIP: Define Discrete Job FormIndicates how to load the bill of material and routinginformation when defining jobs in the Discrete Jobs window.Available Values:

-Concurrent definition:-(Default) Interactive definition:

.

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Setting Up & Implementing WIP

Profile OptionsWIP: Discrete Job PrefixSpecifies the job prefix to use when auto-generating job namesin the Discrete Jobs, Simulate Discrete Jobs, Import Jobs and Schedules, and Auto-Create windows in Work in Process, and in the Planner Workbench window in Oracle Master Scheduling/MRP and Oracle Supply Chain Planning.

WIP: Enable Outside Processing WorkflowsDetermines whether or not outside processing workflows areenabled. The options are Yes and No (Default)

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Setting Up & Implementing WIP

Profile OptionsWIP: Exclude Open ECOsDetermines whether engineering change orders (ECOs) withOpen statuses are excluded while defining jobs/schedules. If so, only ECOs with Release, Schedule, and Implement statuses are implemented when you choose a bill of material revision or revision date and the bill of material is exploded. This profile option also controls whether revisions associated with open ECOs can be selected in the WIP Material Transactions.

WIP: Job Name UpdateableDetermines whether you can update the names of existing jobsin the Discrete Jobs window.

.

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Setting Up & Implementing WIP

Profile OptionsWIP: Move Completion DefaultDetermines the default transaction type for the MoveTransactions window. If you Yes is specified , the transaction type defaults to Complete. Otherwise, the transaction type defaults to Move.WIP: Requirement Nettable OptionDetermines which sub-inventories to include when displayingon–hand quantities in the Material Requirements and View MaterialRequirements windows.Available values

-View only nettable subinventories:-View all subinventories (Default) :

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Setting Up & Implementing WIP

Profile OptionsWIP: See Engineering ItemsDetermines whether jobs and schedules for engineering items can be defined and whether engineering items can be added as material requirements.

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Cr eate and Update Di sc rete

JobsDiscrete Life Cycle

1.Set up discrete manufacturing

2. Define Discrete Jobs

4.Build Discrete Jobs

3.Update Discrete Jobs

4.Close Discrete Jobs

START

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Cr eate and Update Di sc rete

JobsDiscrete Job Definition

(N) WIP > Discrete > Discrete Jobs

Job Name uniquely identifies the job for the Issuing components, Moving/scrapping/ completing assemblies,Charging resources/ overheads and Defining/ updating job definition

Standard - A discrete job controlling material/ operation requirements to build assemblies/collect manufacturing costsNonstandard • A discrete job controlling material andcollects costs for miscellaneous activities, such as Rework, service repair ,Upgrade etc

Job Quantities are used to determine:

Material requirements,Department schedules,Resource load & Job dates.

• Various stages in the life cycle of the discrete job. • When defining a job, only Unreleased/ Released/On Holdstatuses exist

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Cr eate and Update Di sc rete

JobsDiscrete Job Definition

Routing revisionallows you to select which version of the routing you want to use to schedule theoperations and resources.

subinventory in which completed

assemblies will be housed.

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Cr eate and Update Di sc rete

JobsDiscrete Job Definition

Bill Revision allows you to select any valid version of the bill of materialyou want to use to determine the material requirements for the job

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Cr eate and Update Di sc rete

JobsDiscrete Job Definition

You can view material requirements and operations from the Discrete Jobs window as you define andupdate jobs

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Create and Update D iscrete Jobs

Creating Components

When a job is defined , WIP copies the assembly bill created in BOM. It then creates material requirements for the copied bill of material components. Supply types can be used to control how to supply the components for the material requirements on the job.

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Cr eate and Update Di sc rete

JobsDiscrete Job Definition

When you click the Components button on the ‘discrete jobs’ form, the Material Requirements window is displayed with the component information. Here you can view each component’s Main, Quantity, Supply, Comment, and ATP information. For thosecomponents with ATP rules, you can perform an ATP check from this window

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Create and Update D iscrete Jobs

WIP Supply Types

Supply types are defined in the bill of material. If the supply type is changed on discrete job, it overrides the supply types for all the components on that job.

Vendor supplies material directly to WIP Vendor

Material is issued manually before consumptionPush

Operation pull components are issued to the job when the operation is completed.

Operation Pull

These components are not transacted automatically in a job.Bulk

Assembly pull components are issued to the job when the assembly is completed into inventory.

Assembly Pull

Component requirements with supply types from BOM or

those on the Item Master are defaulted when a job is defined.

Based on bill

DESCRIPTIONNAME

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Create and Update D iscrete Jobs

WIP Supply Types

For Phantom supply type , Phantom subassemblies are exploded and their components become material requirements.

Following BOM parameters to control the inheritance of a parent phantom’s operation sequence and whether or not resources and overheads on phantom routings are recognized for costing and capacity planning purposes.

Use Phantom Routings

Inherit Phantom Inherit Phantom Operation Sequence

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Create and Update D iscrete Jobs

Creating Operations

When a job is defined , operations and resourcerequirements are created based on the assemblyrouting.The routing created in BOM is copied tobecome a work in process routing that can bemodified without affecting the BOM routing.

Dates and times for the operations, resourcerequirements, and material requirements needed tobuild the job can be scheduled using detailedscheduling.

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Cr eate and Update Di sc rete

JobsDiscrete Job Definition

When you click the Operations button, the Operations window is

displayed. Here you can view each operation’s

Main, Quantities, Dates, and Description. Also, from

this window, you can display the resource

requirements for a selected operation.

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Create and Update D iscrete Jobs

Update Discrete Job Data

In a discrete job, following information can be updated: Header information, based on the job status Routing information Bill information Sales order information Job operations Job requirements

Note: If the profile option WIP: Job Name Updatable isset to No, the name of the existing job cannot be updated .

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Create and Update D iscrete Jobs

Update/Delete Discrete Job Operations

An operation from a discrete job can be updated /deleted if:

There are no assemblies at the operation. No assemblies have been completed at the operation. There are no pending transactions in the open move interface table. No resources at the operation have been charged.There are no pending transactions in the open resource interface If an operation is deleted , WIP reassigns its material requirements to the first operation in the routing, or to operation sequence 1 if there are no operations in the routing.

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Create and Update D iscrete Jobs

Update/Delete Resources

A resource requirement from a discrete job can be deleted if:

That resource has not been charged to the operation.

There are no pending transactions in the open resource interface table.

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Create and Update D iscrete Jobs

Discrete Work Station

Tool to graphically view and perform manufacturingactivities on the shop floor. This workstation enablesto quickly and easily obtain information critical to supporting business decisions and controlling daily shop floor activities.

Production operators can:

Quickly and easily obtain component and resource requirements, as well as performance measurements.Perform shop floor transactions without returning to the WIP menu.

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Create and Update D iscrete Jobs

Discrete Work Station

(N) WIP > Discrete > Discrete Workstation

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Create and Update D iscrete Jobs

Using Non standard Discrete Jobs

Advantages: Control materials and resources for nonstandard projects. Track costs for various activities. Report on all aspects of production. Manage the activities like :

– Rework– Upgrades– Field service repair and maintenance– Disassemblies– Engineering prototypes –– miscellaneous activities

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Create and Update D iscrete Jobs

Features of Nonstandard Jobs

Assign any predefined bill/routing of material to a nonstandard job.Specify an assembly on a nonstandard job.Include a job quantity on a nonstandard job.Add the same assembly which is being built as a material requirement on the job’s bill of material.Use expense costing to periodically write nonstandard production costs to expense accountsDefine the WIP accounting class as an asset or as anexpense to the job.

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Scheduling Discrete Jobs

Business Needs Planning material and resources quickly and accuratelyEstablishing appropriate planning time fences for productsCreating purchase orders for material accounting for vendor lead timeScheduling material to arrive at the operation where it is consumedScheduling each resource at the operation where it is consumedPromising accurate product shipment dates

Scheduling Jobs

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Scheduling Discrete Jobs

Oracle Manufacturing supports two schedulingmethods for discrete production: dynamic lead-timeoffsetting and detailed scheduling.

Dynamic Lead-Time Offsetting:

Estimating the start date of an order, an operation, or a resource based on order quantity, lead times, and the workday calendar.

Scheduling Methods:

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Detailed scheduling:

Jobs are scheduled to the minute based on detailed resource availability and usages. Oracle Bills of Material calculates manufacturing lead times using detailed scheduling. Detailed scheduling is the most precise method in Oracle Manufacturing.

Scheduling Methods:

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Scheduling Discrete Jobs

Preprocessing lead time: The time required to release a purchase order or a job from the time the requirement is known.Post processing lead time: The time to make a purchased item available in inventory from the time it’s received.Processing lead time: The time required to procure ormanufacture an item. Processing lead time includes the fixed and variable portions of lead times.

Lead Time Elements

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Scheduling Discrete Jobs

Cumulative manufacturing lead time: Total time required to make an item if all raw materials are in stock but all subassemblies will have to be made level by level; Oracle Bills of Material automatically calculates this value.

Cumulative total lead time: Total time required to make an item if no inventory existed and all the raw materials and make all subassemblies will have to be ordered level by level; Oracle Bills of Material automatically calculates this value.

Lead Time Elements

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Scheduling Discrete Jobs

Processing Lead time:Oracle Bills of Material computes the fixed and variable portions of processing lead time using routings and detailed scheduling.Fixed lead time: That portion of time required to build an assembly that is independent of order quantity—for example, setup or teardown.Variable lead time: That time required to produce one additional unit of an assembly.These lead times are used by Oracle Manufacturing indynamic lead-time offset calculations

Lead Time Elements

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Scheduling Discrete Jobs

Calculating Processing Lead Time for Manufactured Items:

The algorithm schedules one discrete job for a quantity of zero (fixed lead time) and a second discrete job for the lead-time lot-size quantity (variable lead time).

When computing processing lead time, all calendar days are considered as workdays, regardless of days off or workday exceptions.

Lead Time Elements

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Business Needs

Detailed scheduling is a method of scheduling production that considers minute-to-minute resource availability information as well as exact routing resource requirementsJob completion dates and times for assembly supply availabilityJob start dates and times for job releaseOperation starts and completion dates and times .Operation start dates and times for component demand requirementsResource load information for capacity planning

Detailed Scheduling

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Scheduling Discrete Jobs

Resource requirement: The amount of a resource that is required to perform an activity in a routing of a job.

Resource availability: The availability of a resource, taking into account the manufacturing calendar, including workday exceptions, shifts, and shift exceptions.

Critical path: The sequence of resources in the routing of ajob that are used to schedule the job.

Overlap: A situation in which two or more scheduled resources can operate at the same time. This can be in one operation or across consecutive operations.

Detailed Scheduling: Key Terms

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Scheduling Discrete Jobs

All resources that have the Scheduled attribute set to Yes, Prior, or Next must have a time-based unit of measure.

All resources that have a unit of measure that is not time-based, such as U.S. dollars, kilograms, or gallons, must have the Scheduled attribute set to No.

Oracle Capacity performs resource load analysis only for resources with a time-based unit of measure.

Scheduling Rules

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Scheduling Discrete Jobs

Scheduling Methods: Oracle WIP Versus Oracle Planning

Uses lead-time offset to schedule

discrete jobs without routings to the

day

Uses lead-time offset to

schedule planned orders for

assemblies with routings and

without routings to the day

Uses detailed scheduling to schedule

discrete jobs with routings to the

minute

Compresses jobs to start on the

current date if the calculated

start date would be in the past

Schedules jobs into the past if

backward scheduling past the current

date

Schedules all planned orders

backward from the due date

Schedules all discrete jobs backward

or forward

Oracle PlanningOracle WIP

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Create and update Repetitive schedules

Repetitive Schedule

A repetitive schedule builds an assembly on a production line at a specific daily rate for a specific number of processing days.

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Create and update Repetitive

schedules Discrete Life Cycle

1.Set up Repetitive manufacturing

2. Define Repetitive Schedules

4.Build Repetitive Assemblies

3.Update Repetitive Schedules

5.Stop repetitive schedules and analyze repetitive Costs

START

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Create and update Repetitive

schedules Repetitive Schedule Elements

Daily Quantity: The number of completed assemblies that are planned to be produced each day. The daily rate can be any positive number/decimals.

Days: The planned number of working days, from the first unit start date to the last unit start date. The processing days can be any positive number/decimals.

Total Quantity: The number of completed assemblies that are planned to be produced.Note: If you enter any two of the three values, thethird one is automatically computed.

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schedules Repetitive Schedule Dates

First Unit Start Date (FUSD): The date and time to beginproduction of the first assembly on a repetitive schedule.Equal to start of lead time

First Unit Completion Date (FUCD): The date and time to complete production of the first assembly on arepetitive schedule. Equal to FUSD plus the lead time

Last Unit Start Date (LUSD): The date and time to beginproduction of the last assembly on a repetitive scheduleCalculated based on the FUSD, repetitive processing days, and hourly production rate

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Create and update Repetitive

schedules Repetitive Schedule Dates

Last Unit Completion Date (LUCD): The date and time to complete production of the last assembly on a repetitive schedule. Equal to LUSD plus the lead time

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Create and update Repetitive

schedules Repetitive Schedule Definition(N) WIP> Repetitive Manufacturing > Associating Lines and Assemblies

The hourly production rate determines how fast each line can produce thisassembly.

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Create and update Repetitive

schedules Repetitive Schedule Definition

(N) WIP> Repetitive> Repetitive Schedules

Various stages in the life cycle of the Repetitive schedule. When defining a schedule , only Unreleased/ Released/On Hold statuses exist

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Scheduling Repetitive production

Business needs:

Optimized use of line capacity

Effectively sequenced repetitive production

Time-phase repetitive component demand and assembly availability

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Scheduling Repetitive production

Elements of Repetitive Line Scheduling

Minimum rate: The minimum number of completed assemblies a production line can produce per hour.

Maximum rate: The maximum number of completed assemblies a production line can produce per hour.

Line lead time: Time required to complete the 1st assembly on a production line starting from the 1st operation to completion into inventory.

Hourly production rate: The rate at which the production line can assemble items.

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Elements of Repetitive Line Scheduling Line start time: The time a production line starts

running every day. The line start time is used to schedule repetitive schedules on a line.

Line stop time: The time a production line stops running every day. The line stop time is used to schedule repetitive schedules on a line.

Daily line capacity: The daily production rate of assemblies on a production line. This is equal to the hourly production rate times the line production hours.

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Elements of Repetitive Line Scheduling

Daily rate: The number of completed assemblies a

repetitive schedule plans to produce per day. Also known as a production rate.

Repetitive processing days: The number of days you plan to work on a repetitive schedule, from the first unit start date to the last unit start date.

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Repetitive Line Scheduling

Daily quantity is used to specify how many

assemblies per day to build

Days are used to specify for how many days

an assembly is to be produced at the specified rate

Line minimum and maximum daily rate can be used as a guideline for the daily quantity of schedule

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Repetitive Line Scheduling

Can specify to the minute the start and completion dates and times of your repetitive schedule

Can schedule to the minute each day the operations and resources of the schedule.

Can schedule all the requirements based on operation dates each day of the schedule.

Must enter either the first unit start date and time and the first unit completion date and time, or the last unit start date and time and the last unit completion date and time, in order to define the lead time for a routing less assembly running on a routing-based line.

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Scheduling Repetitive production

Repetitive Line Scheduling

The top horizontal line indicates the constant hourly production rate that was defined for the line for this assembly.

Schedule production hours =quantity per day/ hourly production rate.

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Scheduling Repetitive production

Repetitive Line SchedulingEach shaded area represents the quantity produced (the daily rate) in a day.The un shaded area represents idle time for this assembly on this line.

The total quantity for the schedule is processing days times daily rate i.e.. the sumof all the shaded areas.

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Scheduling Repetitive production

Repetitive Line Scheduling

Repetitive schedules based on suggestions from Oracle Planning or any other planning system can be defined.

Schedules are loaded into Oracle WIP with a status of Pending—Mass Loaded due to following reasons:

-MRP does not consider existing schedules. Implementing these schedules without looking at existing ones can result in overproduction.

-MRP-suggested schedules may overlap with existing schedules, which is not allowed.

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Scheduling Repetitive production

Repetitive Line Scheduling

Not allowing overlap enables WIP to perform flow charging for repetitive schedules. (Flow charging is when a repetitive assembly and line is charged rather than a specific job. It is based on FIFO.

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Work in Process Transactions - Moves and Resources

Work In Process Flow -Definitions

Types of Material Transactions

Issue transaction is a material transaction to issue component items from inventory to work in process.

Replenishment transaction is a material transaction to stage components in advance of backflushing.

Return transaction is a material transaction to return components from WIP back to inventory. Return transactions increase WIP material requirements, inventory balances, and valuation, and decrease WIP valuation.

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Work In Process Flow -Definitions

Types of Material Transactions

Material issue transactions fulfill WIP material requirements on jobs or schedules. These reduce inventory balances and valuation & incur WIP costs and increase WIP valuation.Supply types are used to control how components are supplied to fulfill material requirements.Push issue transaction is a material transaction to issue component items from inventory to work in process before you manufacture the assembly.

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Work In Process Flow -Definitions

Types of Material Transactions

Backflush transaction is a material transaction that automatically issues component items into work in process from inventory when you move or complete the assembly. A backflush transaction is also known as post–deduct or pull.

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Work in Process Transactions - Moves and Resources

Move Transactions

Move transactions move assemblies from any operation on the routing to any other operation. Moves normally follow the sequence as per routing.

Move Transactions can initiate other transactions - Backflush issue transactions for components with supply type Operation Pull- Automatic resource transactions for resources with autocharge type WIP Move- Overhead transactions for overheads with basis type Item or Lot

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Move Transactions

Intraoperation moves are assembly moves within an operation. Intraoperation steps are phases within an operation used to track assembly locations in detail. The steps are Queue, Run, To Move, Reject, and Scrap.

Operation completions occur when quantities move into to move, reject, or scrap.

Interoperation moves are assembly moves from one operation to another in a routing.

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Move Transactionsautocharge flag controls operation completions and associated automatic transactions.

Count point determines the default for the next operation for a move transaction.

Backflush flag controls when to process Backflush transactions.

It’s advisable that the Backflush flag of the last operationon a routing always be set to Yes, to make sure that all components are issued.

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Work in Process Transactions - Moves and Resources

Backward Move TransactionsBackward move is used to correct a mistake or to perform additional work at a previous operation. An operation can be uncompleted by reversing any of the moves that constitute operation completion

When an operation is uncompleted, system automatically reverses any backflushing transactions that have taken place during the forward move.

On uncompletion, system automatically reverses WIP move resource charges. Automatic resource charges for Lot-based resources are reversed when all assemblies have been uncompleted at the operation.

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Move Transactions

WIP (N) Move Transaction > Move Transactions

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Overcompletions

Can over move or over complete within tolerance Move and complete more assemblies than at

operation

Assignment of Shop Floor Statuses(N) Move Transaction > Shop Floor Statuses > Assign Shop Floor Statuses

System provides an option that prevents users from performing move transactions over operations and intraoperation steps that have No Move statuses, depending on the autocharge types of the operations.

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Costing Move Transactions: Accounting Entries

Costing Backflush Material Transactions

Move transactions can automatically launch backflush

transactions and charge resources and overheads.

Backflush material transactions increase WIP valuation

and decrease inventory valuation.

The accounting entries for backflush material transactions:Account Debit CreditWIP accounting class valuation accounts XXInventory valuation accounts XX

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Costing Move Transactions: Accounting Entries

Costing Move-Based Resource Transactions

Resource charges increase your work in process valuation.

The accounting entries for resource transactions:

Account Debit CreditWIP accounting class resource XXvaluation accounts

Resource absorption account XX

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Costing Move Transactions: Accounting Entries

Costing Overhead Charges

Overhead charges increase work in process valuation.

The accounting entries for overhead transactions:

Account Debit CreditWIP accounting class overhead account XXOverhead absorption account XX

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Costing Backward Move Transactions

Costing Move Transactions: Accounting Entries

Overhead charges reversed if default basis is Item.

Reversed if default basis is Lot only if the move results in zero net assemblies completed in the operation

Overhead charges

only WIP Move resource charges are reversed.

Resource charges

YesBackflush material

Reversed.Charges

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Work in Process Transactions - Moves and Resources

Overhead Charging

Fixed amount for each

resource unit charged

Resource unitsResource-based

overhead charging

Fixed amount for

first unit completed

Lot

Percentage of the

resource value

Resource value

Fixed amount per itemItemMove-based

overhead charging

Overhead ChargeDefault BasisCharging Method

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Work in Process Transactions - Moves and Resources

Overhead Charging

Move-Based Overheads

Upon completion of an operation, system automatically

charges move-based overheads. Move based overheads are

overheads that have a default basis of Item or Lot. Upon

uncompletion, overhead charges are reversed. For Lot-based

overheads, charges are reversed when all assemblies have been uncompleted at the operation.

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Work in Process Transactions - Moves and Resources

Overhead Charging

Resource-Based Overheads

If the operation completion move resulted in automatic

resource charges for WIP Move resources, and these

resources have associated overheads, the overheads will be

charged when the resource is charged. Therefore, a move

transaction that completes an operation can result indirectly in

resource-based overhead charges. Resource-based overhead

charges are reversed when the resource transaction is

reversed.

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Work in Process Transactions - Moves and Resources

Managing Rejected Assemblies

Definitions:

Reject is an intraoperation step in an operation at which assemblies that require rework or need to be scrapped are recorded.

Scrap is an intraoperation step at which assemblies that cannot be reworked or completed are moved.

Scrap account is an account used to charge scrap transactions.

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Work in Process Transactions - Moves and Resources

Managing Rejected Assemblies

There are five ways to manage rejected assemblies in WIP

Move rejected assemblies to Reject. Scrap rejected assemblies. Add rework operation. Inline rework. Rework in a nonstandard job.

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Work in Process Transactions - Moves and Resources

Managing Rejected Assemblies

Move rejected assemblies to Reject. Rejected assemblies can be moved to the Reject

intraoperation step to possibly rework them at that operation or later move them to Scrap.

Benefits Isolates questionable assemblies. Works well if there is space near the work center to

temporarily store the questionable assemblies (same operation, same department). Option to scrap or recover the questionable assemblies.

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Work in Process Transactions - Moves and Resources

Managing Rejected Assemblies

Scrapping Rejected Assemblies Assemblies that cannot be recovered can be moved to the

Scrap intraoperation step.

Benefits Isolates material. Deducts from MRP supply on standard discrete jobs. Offers the option to write off scrap immediately instead of

waiting for the job close (standard discrete/nonstandard asset jobs) or period close (repetitive/nonstandard expense jobs).

Offers the option to undo the transaction later if necessary.

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Managing Rejected Assemblies

Reworking Rejected Assemblies rejected assemblies can be reworked directly in the job by

adding a rework operation in the WIP routing.

Benefits Use predefined rework operations for repeatable rework

activities. Add the rework operation when necessary. Easily charge incremental material, resource, and overhead

costs at rework operation.

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Work in Process Transactions - Moves and Resources

Managing Rejected Assemblies

Reworking Rejected Assemblies rejected assemblies can be reworked directly in the job by

adding a rework operation in the WIP routing.

Benefits Use predefined rework operations for repeatable rework

activities. Add the rework operation when necessary. Easily charge incremental material, resource, and overhead

costs at rework operation.

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Managing Rejected AssembliesInline Rework Can use a routing with a rework operation and rework rejected

assemblies directly in the job/schedule. This is a std operation with a Count point No and the resources charge type Manual.

Benefits Allows to predefine & use the rework operation on the routing

when rework is anticipated. Rework can be performed on a repetitive production line

(Previous option applies only to discrete jobs as operations can’t

be added to a repetitive routing). Can easily charge incremental material/resource/overhead at

rework operation.

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Work in Process Transactions - Moves and Resources

Managing Rejected Assemblies

Using a Nonstandard Job to Rework Assemblies

Can rework rejected assemblies currently in an MRB subinventory using a nonstandard job.

Optionally you can store the assemblies in that subinventory until you are ready to rework them.

Benefits Standardization of Process

Can use a separate Accounting class to track such orders

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Work in Process Transactions - Moves and Resources

Charging Resources

Resource is a thing of value, except material and cash, that is required to manufacture, cost, and schedule products. Resources include people, tools, machines, services purchased from a vendor, and physical space.

Resource basis is the basis for resource usage quantity that indicates whether that quantity is required per item or per lot.

Lot-based resources are resources whose usage quantity represents the amount required per job or schedule. For example, it could be setup time for a machine.

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Work in Process Transactions - Moves and Resources

Charging Resources Item-based resources are resources whose usage quantity represents the amount required per assembly you make. For example, it could be the amount of time required to process each assembly at an operation for the job.

Resource transaction is a transaction where resource costs are charged to a discrete job or repetitive schedule. Transacting a resource is synonymous with charging a resource.

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Work in Process Transactions - Moves and Resources

Charging Resources WIP Move Resource : A WIP move resource is a resource that is automatically charged to a discrete job or repetitive schedule by a move transaction that completes an operation. The autocharge type for this type of resource is WIP Move.

Manual Resource: A manual resource is a resource that you manually charge to a discrete job or repetitive schedule. The autocharge type for this type of resource is Manual.

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Work in Process Transactions - Moves and Resources

Charging Resources Manually Charging Resources

Resources can manually be charged to a discrete job/repetitive assembly and line with or without an associated move transaction.

Manually charging resources without a moveManually charging resources with a moveManually reversing resource charges

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Work in Process Transactions - Moves and Resources

Charging ResourcesManually Charging Resources with a Move

Move transaction can be performed normally .Resources with an autocharge type of Manual assigned to the operations completed during the move can be charged. (WIP displays those resources automatically).If the standard rate flag for a manual resource is No, and the resource type is Person, the resource can be charged at the employee labor rate instead of the standard rate by specifying an employee identifier.This transaction is done from the Move Transactions window using Resources button. WIP (N) Move Transaction > Move Transactions (B) Resources

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Work in Process Transactions - Moves and Resources

Charging ResourcesManually Charging Resources without a Move

Any resource assigned to an operation in a job or schedule can be charged.

Any resource not previously assigned to an operation in a job or schedule can be charged. The resource must be defined for the department associated with the operation. It can have autocharge type Manual/WIP move.

This transaction is done by navigating to the Resource Transactions window.WIP (N) Resource Transactions > Resource Transactions

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Charging ResourcesManually reversing Resource charges

User can manually reverse resource charges at any time by specifying negative resource units applied.

This transaction is done by navigating to the Resource Transactions window.WIP (N) Resource Transactions > Resource Transactions

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Work in Process Transactions - Moves and Resources

Charging ResourcesAutomatic Resource Transactions

Automatically charging resources at standard rate Completing an operation and automatically charging resources Reversing resource charges

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Work in Process Transactions - Moves and Resources

Charging ResourcesAutomatically Charging Resources at Standard Rate

Resources can be automatically charged at their standard rate to a discrete job or repetitive assembly and line while performing a move transaction.

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Work in Process Transactions - Moves and Resources

Charging ResourcesCompleting an Operation and Automatically Charging Resources

All resources with an autocharge type of WIP move are charged at their standard rate.

WIP move resources with a basis type of Item are charged upon completion of each assembly at the operation the resource is tied to.

WIP move resources with a basis type of Lot are charged upon completion of the first assembly at the operation the resource is tied to.

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Charging ResourcesReversing Resource Charges

If an uncompletion is performed, system automatically reversesany resource charges associated with the completion for WIP move resources.

If a WIP move resource has a basis type of Lot, system reverses the resource charges only if all assemblies are uncompleted at the operation.

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Work in Process Transactions - Moves and Resources

Charging Multiple SchedulesFlow charging is a repetitive transaction method in which system charges material, move, resource, and overhead transactions to a specific assembly on a line rather than a specific repetitive schedule.

If more than one schedule has a status that allows charges, user can perform transactions against the consolidated sum of all the schedules.

For example, if there are three schedules for 100 units each with status Released for the same assembly and line combination, up to 300 units could be moved with one transaction.

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Charging Multiple SchedulesAdvantages of Flow Charging

Flow charging means that shop floor data entry can be performed by charging against the assembly and line. Flow charging means that all transactions against an assemblyon a line can be batched and then enter all of them in one transaction. Flow charging supports the idea of a schedule being less of an individual entity than a discrete job is. As long as two schedules build the same assembly on the same line, system does not distinguish between them for transaction purposes.

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Charging Multiple SchedulesRepetitive Allocation

Repetitive allocation is a system technique for applying transaction quantities and costs across several repetitive schedules that are building the same repetitive assembly on the same line.The repetitive allocation algorithm allows the system to allocate the transactions that were flow charged to particular schedules.

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Costing Resource Charges at Resource StandardResource charges increase work in process valuation. Theaccounting entries for resource transactions are:Account Debit CreditWIP accounting class resource valuation account XXResource absorption account XX

The accounting entries for negative manual resource transactions and backward moves for WIP move resources are:Account Debit CreditResource absorption account XXWIP accounting class resource valuation account XX

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Work in Process Transactions - Moves and Resources

Costing Labor Charges at ActualFor labor charges using an actual or employee rate for a resource with the Standard Rate check box clear, the job or schedule is debited at the actual or employee rate. The employee rate used needs to be set up at the organization level. The absorption account is credited at the same rate. The variance between actual and standard is captured at the time of accounting close.

accounting entries for resource transactions are:Account Debit CreditWIP accounting class resource valuation account XXResource absorption account XX

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Costing Resource TransactionsIf the actual rate is greater than the standard rate, the accounting entries are:Account Debit CreditWIP accounting class resource valuation account XXResource rate variance account XXResource absorption account XX

If the actual rate is less than the standard rate, the accounting entries are:Account Debit CreditWIP accounting class resource valuation account XXResource rate variance account XXResource absorption account XX

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Weighted Average costing

Material can be charged to WIP at average cost.

Resources can be charged to WIP at actual or average cost.

Outside processing resources can be defined under average costing.

The average cost of completed assemblies in WIP can be calculated.

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Complete Discrete Jobsand Repetitive Schedules

Completing JobsDefinitions

Assembly completion transaction is a material transaction in which assemblies are received into inventory from a job or repetitive assembly/line upon completion of the manufacture of the assembly.

Completion subinventory is an inventory location at the end of production line or shop floor routing where completed assemblies from work in process are received . This is often the supply subinventory for subassemblies or finished goods inventories for final assemblies.

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Complete Discrete Jobsand Repetitive Schedules

Completing JobsCompletion Transaction Process

The finished assemblies are received into inventory, either to be used as subassemblies or to be shipped as finished goods.

All Assembly Pull material attached on the bill is backflushed.

The quantity in the To Move step of the last operation is decreased, if there is a routing.

The Quantity Complete on the job or repetitive schedule is increased.

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Complete Discrete Jobsand Repetitive Schedules

Completing JobsCompletion Transaction Process

If the quantity completed equals the total quantity for a schedule, and there are other active schedules following it on the assembly/line, the schedule’s status is changed to Complete—No Charges. If the schedule is the last active schedule, its status is changed to Complete.

Job and repetitive schedule statuses are automatically updated to Complete when the total number of assemblies completed and scrapped on a job or repetitive schedule is greater than or equal to the required quantity.

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Complete Discrete Jobsand Repetitive Schedules

Completion Transactions

Complete assemblies from jobs and repetitive schedules into inventory

Return completed assemblies from inventory to jobs and repetitive schedules

over-complete assemblies

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Complete Discrete Jobsand Repetitive Schedules

Completion Transactions(N) WIP > Material Transactions > Completion Transactions

Assemblies can be over completed to inventory from jobs and schedules per established tolerance limits without changing the job start quantity.

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Complete Discrete Jobsand Repetitive Schedules

Work order less completions

Using work order-less completions: Complete assemblies without having to create a job

or schedule Do several tasks in one step at completion Substitute components Support lot and serial number control Cost transactions using standard and average

costing

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Complete Discrete Jobsand Repetitive Schedules

Work order less completions(N) WIP > Material Transactions > Workorder-less Completion Transactions

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Complete Discrete Jobsand Repetitive Schedules

Returning Assemblies from Inventory to WIP

Completed assemblies can be returned to work in process

using the Completion Transactions window as well as the Move Transactions window.

Reasons to Return Assemblies to WIP User want to perform additional processing. User found a quality problem. User mistakenly completed unfinished assemblies to

inventory. User performing a disassembly using a nonstandard job.

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Complete Discrete Jobsand Repetitive Schedules

Returning Assemblies from Inventory to WIP

Return Characteristics User can return assemblies from inventory to WIP by

selecting Return as the transaction type. User can return as many assemblies as needed. Any assembly pull components that were backflushed

upon completion are unbackflushed; that is, they are returned to inventory when you return the assembly to work in process.

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Costing Completion Transactions

Costing Assembly Completion Transactions

Completion transactions decrease work in process valuation and increase inventory valuation. The accounting entries for assembly completion transactions are:

Account Debit Credit

Subinventory elemental

accounts XX

WIP accounting class

valuation accounts XX

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Costing Completion Transactions

Earning Assembly Material Overhead on Completion Overheads can be assigned based on the total value of

an item. These overheads can be earned as assemblies into

are completed into inventory. The accounting entries are:

Account Debit Credit

Subinventory material overhead

account XX

Inventory material overhead

absorption account XX

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Manufacturing Average Costing

Items can be costed at a weighted average perpetual cost. Completions are valued using the sum of the actual costs of

resources and materials issued to a job Partial completions are valued using the appropriate

proportional sum of actual resource and materials issued to a job

Final completions are valued using the total net value in a job

The unit cost of a completion is computed elementallyMaterial ,Material and overhead ,Resource, Overhead &Outside processing

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Completion Transactions for Repetitive Schedules

Roll forward Rules When all assemblies of a schedule are completed, WIP

checks the schedule for any excess components resulting from over issue of material requirements.

If the subsequent schedule is released, or if it is unreleased and falls into the auto release time fence, WIP rolls the excess material charges forward to that schedule.

If there is no subsequent schedule to auto release, WIP does not roll the excess material charges forward.

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Completion Transactions for Repetitive Schedules

Autorelease Repetitive production can be streamlined by automatically

releasing the next schedule when one schedule is completed.

A line can continue running and build repetitive assembly if another schedule is defined for the assembly on that line.

If the schedule is defined but unreleased, the completion of the preceding schedule can serve as a signal to automatically release the next unreleased schedule.

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Closing Discrete JobsCan the Status of a Closed Job Be Changed? To be able to unclose jobs, the Close Discrete Jobs function

security parameter must be set to Y. Only jobs closed in error should be unclosed, it should be

done this immediately after the close using the Close Discrete Jobs window.

If assembly costs are rolled up between the time a job is closed and unclosed, costs may be incorrect because the unclose process does not revalue the job.

A job that is linked to a sales order cannot be unclosed. A job that was closed in an accounting job that is no longer

open cannot be unclosed

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Work In P rocess Interfa cesWIP Interfaces

Open Move Transaction Interface Open Resource Transaction Interface Work Order Interface

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Work In P rocess Interfa cesWIP Interfaces

Open Move Transaction Interface This interface is used to transfer WIP move transaction

information into Oracle Applications. The records can be loaded into the Open Move Transaction Interface from a variety of sources, including external data collection devices such as bar code readers, automated test equipment, cell controllers, and other manufacturing execution systems.

The interface validates the records & marks invalid transactions, so that the transactions can be corrected & resubmitted

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Open Move Transaction Interface

This interface enables users to perform many of the functions

possible from the Move Transactions window. Move assemblies between operations and intra-operation steps Scrap assemblies Move assemblies from an operation and complete them into

inventory with a single transaction Over-complete a quantity greater than the job or schedule

quantity if over-completions are enabled Return assemblies from inventory and move to an operation

with a single transaction

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Open Move Transaction Interface

Ad hoc operations cannot be added through this interface even if the WIP Allow Creation of New Operations parameter is set.

The table populated while inserting records into the interface is WIP_MOVE_TXN_INTERFACE

Types of move transactions

Move transaction

Move Completion

Move Return

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Open Move Transaction Interface Columns to be populated:FM_INTRAOPERATION_STEP_TYPE,FM_OPERATION_SEQ_NUM,

LINE_CODE, ORGANIZATION_CODE, PROCESS_PHASE,

PROCESS_STATUS, TO_INTRAOPERATION_STEP_TYPE,

TO_OPERATION_SEQ_NUM, TRANSACTION_DATE,

TRANSACTION_QUANTITY, TRANSACTION_UOM, WIP_ENTITY_NAME

FM_INTRAOPERATION_STEP_TYPE,FM_OPERATION_SEQ_NUM

are only required for move transaction/ completion transactions TO_INTRAOPERATION_STEP_TYPE,TO_OPERATION_SEQ_NUM are

only required for move transaction & move return transactions

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Open Resource Transaction Interface

This interface is used to charge resources. External data collection devices such as bar code readers, payroll systems, and time card entry forms can be used to collect resource and overhead transaction data, then load the data into the Open Resource Transaction Interface for WIP to process.

The interface validates the data and marks any that are invalid so that it can be corrected and resubmitted.

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Open Move Transaction Interface

This interface enables users to perform many of the functions

possible from the Resource Transactions window. Charge labor resources Charge overhead resources Charge outside processing resources Add ad hoc resources

Note: Non-person resources cannot be charged at an actual

usage rate or amount through the Resource Transactions

window. This feature is unique to the Resource Transaction

Interface.

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Open Move Transaction Interface

The table populated while inserting records into the interface is

WIP_COST_TXN_INTERFACE

Columns to be populated:OPERATION_SEQ_NUM, ORGANIZATION_CODE, ORGANIZATION_ID,

PROCESS_PHASE, PROCESS_STATUS, RESOURCE_SEQ_NUM, TRANSACTION_QUANTITY, TRANSACTION_DATE, TRANSACTION_TYPE, TRANSACTION_UOM, WIP_ENTITY_NAME

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Open Move Transaction Interface PROCESS_PHASE describes the current processing phase of the

transaction. The Cost Worker processes each transaction row

through the following two phases

Values: 1 Resource Validation ,2 Resource Processing PROCESS_STATUS contains the state of the transaction.

Values: 1 Pending , 2 Running ,3 Error TRANSACTION_TYPE should be set to:

Values: 1 for normal resource transactions,2 for overhead transactions & 3 for outside processing transactions

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Work order Interface

The Work Order Interface enables users to import Discrete job

and Repetitive schedule header information, and Discrete job

operations, material, resource, and scheduling information from

any source, using a single process.

Options available: Planned orders for new Discrete jobs, Discrete job operations, components, resources, resource

usage, and scheduling details, Update and reschedule recommendations for existing Discrete

jobs, and suggested Repetitive schedules

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Work order Interface The Work Order Interface consists of two tables: the

WIP_JOB_SCHEDULE_INTERFACE table (Open Job and Schedule Interface table), and the WIP_JOB_DTLS_INTERFACE table (WIP Job Details Interface table). Header information is loaded into the WIP_JOB_SCHEDULE_INTERFACE table, and operations, components, resources, and scheduling information into the WIP_JOB_DTLS_INTERFACE table.

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Work order Interface The Work Order Interface consists of two tables: the

WIP_JOB_SCHEDULE_INTERFACE table (Open Job and Schedule Interface table), and the WIP_JOB_DTLS_INTERFACE table (WIP Job Details Interface table). Header information is loaded into the WIP_JOB_SCHEDULE_INTERFACE table, and operations, components, resources, and scheduling information into the WIP_JOB_DTLS_INTERFACE table.

Page 188: Oracle WIP

Picki ng for Man ufacturi ng Picking for Manufacturing

Introduced in 11.5.7 Family pack for manufacturing Combines the functionality of Manufacturing & Warehouse

management system to provide rule based component picking..

Operation or assembly pull material can be excluded from the tasks.

Migration to the new Picking for Manufacturing is optional for WIP users.

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Picki ng for Man ufacturi ng Picking for Manufacturing

Move orders will be created for all component requirements. Picking supports discrete/lot based jobs, as well as flow & repetitive schedules.

The use of move orders will allow users to use the standard inventory picking rules, as well as to track and transact the component requirements.

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Picki ng for Man ufacturi ng

Supply type push

- Material issued directly to job

- Transacting the move order / task decrements inventory Supply type assembly / operation pull

- Material moved to supply subinventory

- Material pulled at operation move or assembly completion

- Optionally excluded from process

Picking for Manufacturing

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Picki ng for Man ufacturi ng

Pick release selected jobs

-Use Inventory Rules to allocate material

-Allocated material cannot be used for other transactions

-Create move orders for the required material

-Missing material is backordered and available for re-release

Optionally print move order pick slip report Move order transacted on desktop

-Query on specific jobs or schedules

-Update allocations if necessary

Picking for Manufacturing

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Picki ng for Man ufacturi ng Picking for Manufacturing

Current Functionality in Release 11.5.9 User can specify upto which operation the material needs to be

pick released for a single or set of jobs. Various picking methodologies (like cluster pick, bulk pick, zone

pick etc.) supported by Order management also can be used. However this feature is limited to Discrete jobs only.

All the material requirements for a job is released under a single move order irrespective of the supply types.

User will have the option on printing of the pick slips at the time of pick release. .

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Picki ng for Man ufacturi ng Picking for Manufacturing

Current Functionality in Release 11.5.9 User can choose whether to plan tasks by default or not for

each pick release. This option can also be set at organization level and can be overridden by user while pick releasing. .

After the pick release, if allocation was partial, user can check the leftover requirements for a job by clicking on a particular job node.

User can see the backordered quantity for each component.

.

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Picki ng for Man ufacturi ng

.

Picking for Manufacturing(N) WIP> Discrete> Component Pick Release

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Q & A