Training on 11i.10 enhancements for Infosys

1
Training on 11i.10 enhancementsfor Infosys
Oracle Process Manufacturing
5th January 2005
2
Agenda

• Process Manufacturing
• OPM Positioning
• Introduction to OPM
• 11.5.10 Enhancements
• Future Direction
• Questions and Answers

3
Process Manufacturing Market Profile

• Industry Focus
• Pharmaceutical Biotechnology
• Food Beverage
• Chemical
• Metals Paper
• Building Materials

40
Process
Discrete
4
Variabilityand The Supply Chain
Process - it kind of works
Discrete - it works
5
Making Stuff vs. Things
Manufacturing and Supply Chain
Process Manufacturing

• Process Manufacturing
• Uses Formulas
• Mixes, Blends, Transforms
• Makes STUFF

• Discrete Manufacturing
• Uses Bills of Materials
• Builds, Assembles, Fabricates
• Makes THINGS

6
The Physical Inventory Test

• Count the computers, count the coffee

Cup, OZ, CC, ML, inches coffee (cream and
sugar?) Coffee Solids
One
Discrete Assumptions vs. Process Realties
7
Material Changes With Time

• Discrete Assumption
• Constant through time
• Process Realities
• Varies through time

Time
Time
8
How Different are they?

• Parts to Ingredients
• BOM to Formula
• Each to Batch (Bulk)
• Rework to Recycle
• Scrap to Byproduct
• UOM to Multiple UOM
• Constant to Variability
• Specification to Attributes

9
 Discrete Item Number Location Quantity
 Simple Process Item Number Location Quantity Unit of measure Tank/silo Lot number Aging information Classification
 Complex Process Item Number Location Quantity Unit of measure Tank/silo Lot number Sub-lot number Container ID Container type Aging information Catch weight Classification Quality Hazards Information
10
Bill of Material Assumptions

• Many components make one end item
• The A Bill
• Predictable in what is made
• A B always AB
• Predictable in how much is made
• 11 always 2
• Always made the same way

11
Bill of Material Assumptions
And Process Realities

• Many components make one end item
• The A Bill
• Predictable in what is made
• A B always AB
• Predictable in how much is made
• 11 always 2
• Always made the same way

many
and the V, X and I bills
NO! Fresh vs. frozen ingredients, quality, line,
seasonal differences, etc.
12
Variability in Process Manufacturing
Quality Attributes
Alternative Routings
Potency
Multiple Units of Measure
Multi-Plant Manufacturing
Yields
Viscosity
Complex Costing
Solid
Status
Grade
Fluctuating Commodity Prices
Alternative Formulas
Lot Sizes
Shelf Life
Toxicity
Sequencing
pH Factor
Catch Weight
Seasonality
13
Unique Process Requirements

• Formula Management
• Co-Products By-Products
• Unit of Measure Conversion
• Quality Specifications Control
• Lot Control
• Ageing Expiry
• Yield Loss Factors - No Scrap!

14
Unique Process Requirements

• Lot Traceability
• Packaging
• Regulations FDA MSDS
• Sub Lot Requirements
• Catch Weight
• Scheduling Needs

15
Agenda

• Process Manufacturing
• OPM Positioning
• Introduction to OPM
• 11.5.10 Enhancements
• Future Direction
• Questions and Answers

16
Business Pressures

• Variability
• How do I create consistent products using
  inconsistent ingredients?
• How do I achieve process and reaction stability?

• Regulatory Compliance
• How do I comply with globaland local
  requirements?
• How do I ensure lot traceability and adhere to
  standards suchas 21 CFR Part 11?

• Reduced Time to Market
• How can I manage a growing list of key product
  attributes?
• How can I efficiently mass customize my products?

• Lowest Total Cost
• How can I meet quality, delivery, and service
  demands at a competitive price?

17
Operational Challenges

• Limited joint developmentwith poor recipe reuse

RD LAB
CUSTOMERS
SUPPLIERS

• High variability in release-to- volume-production
  process

• Material push

Materials,Ingredients,Quality Docs
FinishedGoods,Quality Docs
PROCESSING PLANT
By- / Co-Products
Step 10
MaterialsInventory
FinishedGoods
Step 30
Step 40
Step 50
Step 20
Waste

• Documentation required at every step for
  traceability compliance
• No status visibility between supply chain
  partners
• Inefficient material and capacity utilization

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A Need for Change
Leading Business Trends

• Computer Assisted Recipe Formulation
• Process Flexibility with Rapid Changeover
• Renewed Emphasis on Product Safety Traceability
• Increasing Collaboration with Suppliers
• Continued Focus on Cost Containment

19
Process Industry Value Chain
Suppliers
Finished Product Mfgr
Growers
Manufacturers
Raw Materials
Brand Dev.
Manufacturing
Marketing Research
Distributors
Product Dev.
Retailers
Business
Distribution Channels
Customers
Consumer
Web Direct
20
Oracle Built for Process Industries
CustomerRelationshipManagement
SupplyChainManagement
Develop
Sell
Plan
Finance HR Projects
Market
Source
Maintenance
Service
Process Manufacture
Fulfill
21
OPM for the Industries
22
OPM Customers
23
Consumer Goods Capabilities
Evolution of Oracle Applications in Consumer Goods
Current Differentiators
new in 11i.10
with 11i.9

• Mixed Mode Manufacturing
• Inventory Postponement Optimization
• Supplier Collab VMI
• Collaborative Planning
• Supply Chain Exception Mgmt
• Real Time Order Promising and Visibility
• Multi-Channel Order Capture
• Advanced Pricing
• EDI Transactions for POs, Ship Notices, Invoicing
  Warehousing
• Claims Deductions Mgmt
• Lot Traceability
• Funds Management
• Promotional Planning

• Process Manufacturing
• 21 CFR Part 11 Compliance
• HACCP Quality Test Points
• Automatic Lot Grading
• Manufacturing Scheduler
• High Volume Order Processing
• Continuous Real-Time Demand Planning
• Integrated Maintenance and Production Planning
• Enhanced Blanket Orders and Releases
• Retroactive Promo Adjustments
• Promotional ROI Calculations
• 3rd Party POS Data Import (to Calc Promotional
  Accruals)
• Transportation Execution
• Collaborative Sourcing
• Advanced Product Catalog

• Product Information Hub with UCCNet Support
  (11i.10)
• Discrete Manufacturing
• 21 CFR Part 11 Compliance
• RFID Transactions
• Short Term Deployment Planning
• Transportation Planning
• Scarce Inventory Allocation
• Enhanced Trade Mgmt. Tools
• Business Account Planning
• Integrated Sales Contracts
• Quick Ship User Interface
• Customer Consigned Inventory
• Retroactive Pricing in Purchasing
• Channel Budget Management
• Enhanced Management and Resolution of Promotional
  Claims

Oracle confidential. This is not a commitment to
deliver. Product directions are subject to change
without notice.
24
OPM Consumer Goods Customers
25
Life Sciences Capabilities
Evolution of Oracle Applications in Pharma /
Biotech
with 11i.9
Current Differentiators
new in 11i.10

• 21 CFR Part 11 Compliance for Process
  Manufacturing
• Electronic Signatures
• Electronic Records
• Validation Procedures
• Production Batch Record Keeping System
• Integrated Process Quality Workbench
• Advanced Product Catalog
• CRF Design and Layout Utility
• Direct Entry on PDF Forms-Enabled CRFs
• Multi-Lingual Remote Data Capture Entry
  Monitoring

• Clinical Trials Data Mgmt
• Adverse Event Reporting
• Thesaurus Management
• Clinical Remote Data Capture
• Skills Database
• Process Manufacturing
• Potency Support
• Expiration Dating
• Industry Compliant Recipes
• Lot Traceability Genealogy
• Project Management
• Flow Manufacturing
• Inventory Optimization
• Workflow-Enabled Quality Management

• Computer-Aided Formulation
• Stability Studies Management
• Environmental Testing
• E-Signatures on Documents
• Graphical Recipe Designer
• Mass Quality Control Result Entry
• Multiple Drum Receipt with Automatic Lot
  Numbering
• Enhanced Management Resolution of Chargebacks
• Procurement Contracts
• RFID-Based Transactions

CRF Case Report Form
Oracle confidential. This is not a commitment to
deliver. Product directions are subject to change
without notice.
26
Oracle Life Sciences Customers
27
Chemicals Capabilities
Evolution of Oracle Applications in Chemicals
Current Differentiators
new in 11i.10
with 11i.9

• Computer-Aided Formulation
• Stabilities Studies Mgmt
• Reserve Manufacturing to Sales Orders
• Rapid Recipe Creation
• Lot-Specific Costing
• Environmental Monitoring
• Enhanced Co-Product Planning
• Transportation Planning
• Short Term Deployment Planning
• Customer Consigned Inventory
• Integrated Sales Contracts
• Retroactive Pricing in Purchasing
• Business Account Planning
• Channel Budget Management

• Product Development for Process Manufacturing
• Laboratory Spreadsheet and Formula Analysis
• Dual Unit of Measure for Active Ingredients
• Shelf-Life Status Control
• Co- / By-Products
• Lot Traceability
• Shift Level Reporting
• Asset Maintenance
• Supply Chain Planning and Procurement
• EDI Transactions for POs, Ship Notices, Invoicing
  Warehousing
• MES Integration APIs
• Multi-Channel Order Capture
• Real Time Order Promising and Visibility

• Process Industry Procedures and Business Flows
  for ISO Certification
• 21 CFR Part 11 Compliance
• Sequence Dependent Scheduling
• Quality-Driven Lot Usage and Production Control
• Product Data Management via Process Parameters
• Continuous Real-Time Demand Planning
• Integrated Maintenance and Production Planning
• Transportation Execution
• Collaborative Sourcing
• Advanced Product Catalog
• Enhanced Blanket Orders and Releases

Oracle confidential. This is not a commitment to
deliver. Product directions are subject to change
without notice.
28
OPM Chemical Customers
29
The Process Manufacturing Marketplace

• Suite Vendors offer integrated suite
• Niche Players claim best-of-breed, but require
  large integration efforts

30
Recent Process Press

The Bottom Line Food, Consumer Products,
Chemicals, and Life Sciences customers now have a
single vendor product that can span their
requirements for Process Enterprise Resource
Planning (ERP), Enterprise Asset Management
(EAM), Supply Chain Management (SCM), and Product
Lifecycle Management (PLM).
Source AMR February 2004
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Recent Process Press
In terms of industries again, Oracle's greatest
penetration according to Gartner is in the
manufacturing segments, and with a 7.4 growth in
Process Manufacturing actually slightly outgrew
SAP 
Source Gartner
32
Recent Process Press
"Oracle now leads in overall process ERP depth
and flexibility."

• Meta Group (2004)

33
Recent Process Press
Oracle is setting the new Process ERP benchmark
by extending Process industry functionality into
its full E-Business Suite.

This addresses the full checklist of
capabilities that we suggest customers assess
from their ERP vendors

• AMR 2004

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How Process Mfg Solutions Stack Up...
Ross/CDC
SCT
SAP
Oracle
Capability

-
o

Recipe Rules-Based Production


o

Multi-Level Lot Traceability
-
-


Formula-Based MSDS Development
-
o


Proactive Quality Workflows

-


Multiple Simultaneous Cost Methods
o
-
o
o
Activity-Based /Lot Costing
Notes Good, o Neutral, - Poor
35
How Process Mfg Solutions Stack Up...
Ross/CDC
SCT
SAP
Oracle
Capability


o

Potency Allocations

-


Step-LevelProduction Mgmt
-
-


Electronic Signatures

-
o

Complex Process Modeling


-

IntegratedCatch-Weights
Notes Good, o Neutral, - Poor
36
Top 5 reasons cited for not using SAP R/3
Manufacturing
94 of SAP process manufacturing customers
cited Lacking functionality as number 1 reason
for not using SAP manufacturing
37
Agenda

• Process Manufacturing
• OPM Positioning
• Introduction to OPM
• 11.5.10 Enhancements
• Future Direction
• Questions and Answers

38
Oracle Manufacturing Product Family
Process Mfg.
Fulfill
Maintain and Service
Design
Plan
Procure

• Order Management
• Configurator
• Advanced Pricing
• Release Management
• Inventory Management
• Warehouse Management
• Transportation

• Advanced Supply Chain Planning  
• Inventory Optimization
• Global Order Promising
• Demand Planning
• Collaborative Planning
• Constraint Based Optimization

• Purchasing
• iProcurement
• Sourcing
• iSupplier Portal
• Oracle Supplier Network
• Procurement Intelligence
• Procurement Contracts
• Services Procurement

• Advanced Product Catalog
• CAD View 3D
• Product Intelligence

• Process Inventory
• Product Development
• Process Execution
• Process Planning
• Costing and MAC
• Process Quality
• Regulatory Mgmt
• OPM System Admin
• ERES

• Enterprise Asset Management
• Complex Maintenance, Repair Overhaul
• CRL Financial Management
• Network Logistics (Network Asset Tracking)

39
OPM Understands your Business Flows...
40
OPM Product Development
A secure, configurable environment for bringing
new products to market
RegulatoryDocuments
ExperimentalRecipes
Lab Batches
What-if Analysis
ProductionRecipes
Workflow Based Approvals
Collaborate
41
OPM Product Development Solution

• Secure and Manage Data
• Formula Security, Product Development Workbench,
  Product Lifecycle Management
• Define and Enforce Business Practices
• Change Management, Workflows, Process Parameters
  and Process Instructions, E-records and
  E-signatures
• Accelerate Recipe Development
• Recipe Designer, Default Status, Auto-Recipe
  Generation, Mass Search Replace
• Reduce Costs and Optimize Formulas
• Simulator Optimizer, Formula Analysis

42
Quality Driven Product AttributesManage
Variability / Sustain Product Consistency
Item
9FA123
200F (Aurora Whse)
Warehouse
Aisle 1, Row 1 Level 1 (1-1-1)
Location
Day Code Batch Prod Run
Lot
Pallet Case ID
Sublot
Good/Hold/Reject

• Precise Inventory Tracking
• Shelf life
• Retest interval
• Potency
• User-defined classifications

Status
A
Grade/Spec
LB/EA
Multiple UOM
43
OPM Multiple Units of Measure
Standard 1 Case 10 LB
20.0 LB
vs
Lot 001- A 1 Case 10.5 LB
Lot 001- B 1 Case 10.3 LB
20.8 LB

• Package / Liquid / Solid contents can vary by
  containers
• Track onhand inventory in two units of measure
  simultaneously
• Formulate and Transact in any convertible UOM

44
Multi-Level Material/Resource TraceabilityReduce
Risk to Public Health and Brand Image
Lot Source
Ingredients Resources
Intermediate or Bulk Products
Finished Product
Supplier
Consumers
Where Used

• Improve Recall Responsiveness / Cost
• Comply with FDA GxP and Safety Regulations
• Trace Materials Enterprise-Wide to Analyze Quality

45
Oracle Process Inventory Solution

• Satisfy Customer Demand Quickly and Accurately
• Quality-Driven Product Attributes, Multiple UOM
  Control, Auto Allocation, Lot Expiration
  Management, Grade and Status
• Reduce Costs with Efficient Inventory Management
• Physical Inventory and Cycle Counting, APIs,
  Inquiries and Reports
• Reduce Risk with Rapid Lot Genealogy Analysis
• Lot Genealogy Inquiry, Report and Business
  Intelligence
• Ensure Regulatory Compliance
• Audit Trail, Strong Security, Electronic
  Recordkeeping with Electronic Signatures for 21
  CFR Part 11 Compliance

46
Oracle Process Manufacturing MRPThe Planning
Process
47
Oracle Process Planning MRP Solution

• Balance supply and demand
• Consider all sources of supply and demand
• Applies demand to current inventory balances
• Consider lot expiration of current inventories
• Suggests specific actions based on user defined
  rules
• Purchase, transfer, and production suggestions
• Projects inventory availability dates based on
  MRP recommendations
• Process Planning reports

48
Batch Processing ChecksRequired e-signatures and
QC test completion
Ingredient 2
Ingredient 1
10 Dispense
ResourceActivity Usage/Qty
Ingredient 5
Ingredient 4
ERES
30 Blend
40 Package
Start-to-Start
QC step HOLD
ERES
ResourceActivity Usage/Qty
ResourceActivity Usage/Qty
ERES
WF
By-Product 1
Product 1
20 Weigh
Finish-to-Start
ResourceActivity Usage/Qty
ERES
Ingredient 3
49
Quality-Controlled Batch ProcessingControl
Production Variability with Quality Checks
10 Weigh
ResourceActivity Usage/Qty
30 Blend
40 Package
ResourceActivity Usage/Qty
ResourceActivity Usage/Qty
20 Heat
ResourceActivity Usage/Qty
Hold Step for Quality Sampling and Testing
50
Oracle Process Execution Solution

• Maximize production flexibility
• Flexible scaling
• Increase plant efficiencies
• ASCP, Gantt Chart, Automatic lot allocation
• Streamline reporting using backflushing and APIs
• Incremental backflushing, over 40 APIs
• Achieve product consistency
• Simulator/Optimizor, Process Parameters,
  Processing Instructions, Quality Testing,
  Electronic Records

51
Oracle Process Manufacturing Quality Manage
Variability and Assure Product Consistency

• Inspection Points
• Receipt, WIP, shipping
• Lot expiration/retest
• Environmental monitoring

• Integrations
• Material usage decisions based on lot status and
  grade
• Order allocation (based on results)
• Quality-controlled batch processing

Workflow-Driven Processes and Electronic Records
Standardize
Sample
Analyze
Disposition
Report

• Global Standards
• Tests methods
• Sampling plans
• Specifications
• Input APIs

• Compliance
• Certificate of analysis or conformance
• Lot genealogy
• Electronic recordkeeping

• Results
• Composite result statistics(min/max, std dev,
  average)
• Stability studies
• Output APIs

• Adjust batches
• Change formulation or procedures

ProcessImprovement
52
Workflow-Driven Quality ManagementAutomate
quality tasks and reduce lead times
Require MaterialInspection basedon
Specifications
Sample Creation Notification Workflow
Create Samples
Enter, Evaluate,Composite Results
Testing Notification Workflows
Samples Disposition Workflow
Update ItemLot Status/Grade
53
Oracle Process Quality Solution

• Achieve product consistency
• Stability studies, lot expiration handling, batch
  control
• Enforce proactive quality assurance
• Specification validity rules, sampling,
  environmental monitoring, workflow, e-record and
  e-signatures
• Streamline quality lab productivity
• Automated test/lab assignment, Quality workbench
• Assure customer and regulatory compliance
• Customer spec matching, Certificates of
  Analysis,lot traceability

54
Oracle Process Manufacturing CostingSupport All
Phases of Costing
Material
Indirect
Resource
Overhead
Acquisition
Composite
Actual
Lot
Standard
55
Multiple Costing MethodsSupports different
costing needs
Standard Costing

• Calculates based on formula and routing cost
  rollups

Actual Costing

• Calculates based on actual production data and
  allocations

LotCosting

• Calculates based on actual production data for a
  specific lot

56
Oracle Process Financials Solution

• Optimize Costs Margins
• Multiple cost methods Standard, Actual, Lot,
  Composite, Cost Development Workbench
• Capture precise product costs
• Co-products, by-products, circular references,
  unlimited cost elements, cost allocations
• Facilitate proactive cost management
• Cost monitoring, cost analysis
• Assure proper accounting of Resource inventory
  transactions
• Flexible account mapping, Sub-ledger flow, Drill
  Downs

57
Evolution of Oracle Process Manufacturing
with 11i.9
Current Differentiators
new in 11i.10

• Collaborative, rules-based recipe development
• Ingredient and process variability management
• Optimized capacity and ingredient usage
• Multiple cost methods
• Pre-defined quality workflows
• Supplier customer collaboration
• Real-time WIP visibility
• Lot traceability
• Co-products by-products
• Shelf-life and status control
• Expiration dating
• Potency support

• Integrated process quality workbench
• Manufacturing scheduler with process production
• Electronic signatures and records for 21 CFR part
  11
• Process industry tutor procedures and business
  flows
• Detailed shop floor data management
• Validation procedures
• Production batch record keeping system
• Automatic lot grading
• HACCP quality test points

• Graphical recipe designer
• Lot specific costing
• Computer-aided formulation
• Electronic records and signatures document
  control
• Enhanced customer quality specification matching
• Mass quality control result entry
• Enhanced co-product planning (via advanced
  planning integration)
• Environmental testing
• Multiple drum receipt with automatic lot numbering

58
Agenda

• Process Manufacturing
• OPM Positioning
• Introduction to OPM
• 11.5.10 Enhancements
• Future Direction
• Questions and Answers

59
Topics

• Process Inventory
• Product Development
• Quality Management
• Regulatory Management
• OPM System Administration
• Process Planning
• Process Execution
• Process Costing
• Process Logistics

60
Process Inventory
61
New Feature HighlightsProcess Inventory

• Lot UOM Conversion Update
• Automatic Lot Numbering Configuration
• Process to Discrete Inventory Transfer

62
Lot UOM Conversion Update

• Lot UOM Conversions can be updated if
• Pending transactions do not exist for lot
• No unposted Journal transactions exist for lot
• User has access to this function
• User has organization security for warehouse
  where lot is onhand

• Onhand inventory can be updated
• Tracked via inventory transaction (CONV)
• Audit of lot UOM conversion changes is tracked

63
Auto Lot/Sublot Numbering

• Configurable by item
• User-defined lot and sublot prefix
• Manual override allowed
• Suffix can be reset to fill in numbering gaps
• Custom schemes supported via program exit
• Zero pad option
• Smart sublot suffix
• Sequential for a lot
• Resets for new lot

64
Process-Discrete Inventory Transfer
65
Process-Discrete Inventory Transfer

• New form to transfer inventory between OPM
  organization and Discrete organization
• Controlled release

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Product Development
70
New Feature Highlights
Product Development

• Graphical Recipe Designer
• Automatic Recipe Generation
• Computer Aided Formulation
• Mass Search and Replace for Recipe Validity Rules
• Default Status Generation

71
Recipe Designer
72
Recipe Designer

• Designed for formulators and process engineers
• Enables creation and maintenance of Recipes
• User friendly interface

73
Automatic Recipe Generation
74
Recipe Generation
Upon creating a Formula, a Recipe and Validity
Rule(s) are generated based on user-defined rules
generates
Formula
Validity Rules
Recipe
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Computer Aided Formulation
80
Computer-Aided Formulation Model Production
Requirements to Target Specifications
In-Process QC Metrics
Inventoried Lot Properties
Computer-Aided Formulation

• Recalculate Materialand Yield Quantities
• Compute Batch Characteristics (e.g., fat content,
  potency, etc.)
• Automatically Revise Lot Allocations

Target Product /Customer Specs
Product Recipe

• Optimize Lot Usage / Production Batch Properties
• Use What if Simulation to Streamline Production
  Planning

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Calculated based on the ingredient parameters
89
Formula or Batch Optimization
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Optimization results
94
Optimization results
95
Mass Search and Replace
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Default Status
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Quality Management
103
New Feature Highlights
Quality Management

• Introduced Quality Workbench
• Specifications Sample Monitoring for
  Non-Material sources
• Product Stability Analysis
• Automatic Sample Creation
• Mass Results Entry Association

104
Quality Workbench

• Organize specifications and samples data
• Summary
• Details Tests, Results
• Improve quality laboratory productivity
• Simplify access to Quality screens
• Personalize workbench with saved queries

105
Monitoring Specifications and Samples

• Inspect quality levels of non-material sources
• Warehouses or locations
• Generic or plant resources
• Notify of out-of-spec conditions via the sample
  group rejection workflow
• Examples of uses
• Monitor environmental controls (e.g. temperature)
• Inspect an equipment resource for proper
  calibration
• Validate stability study storage chamber
  conditions

106
Stability Study Management

• Determine shelf life and recommended storage
  conditions
• Assess environmental impact on material quality
• Establish a retest period for similar future
  batches
• Compliance with the US Food Drug Administration
  (FDA) and Good Manufacturing Practices (GMP)

107
Quality-Driven Lot UOM Conversion

• Leverage quality test result(s) to
• Account for lot-to-lot quality variations
• Recommend lot-specific inter-class UOM conversions

• Notify to update conversions and on-hand
  inventory

108
Automatic Sample Creation
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Mass Results Entry
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Regulatory Management
115
Regulatory Management

• Document Creation to Document Management

iSign
E-business Suite
MSDS Document System
Items Properties Formula Sales Info Customer
Info Inventory Balance
Atrion Wercs
116
Regulatory Features

• Document Storage and Retrieval (iSign)
• Document Security
• Approvals Management
• eRecords and eSignatures
• Export APIs
• Items
• Formulas
• Customers
• Specifications
• Technical Parameters
• Item Properties
• Re-build Notifications
• Electronic Distribution

MSDS Generation Software
Supplier MSDS
Customer MSDS
117
OPM Systems Administration
118
Archive and Purge
Archive Process
Test Run
Purge Process
119
Archive and Purge Implementation Steps

• User defined purges
• Some setup can be done through Purge Setup form
• SQL Statement must be loaded directly to table

120
Process Planning
121
OPM Planning

• OPM MRP
• OPM- APS

122
Oracle Process Manufacturing MRP is

• OPM MRP is a typical material planning
  application
• Material planning against dependent and
  independent demand to ensure on-time delivery
• No CRP capacity or resource planning (See OPM
  integration to ASCP, next slide)

123
OPM with ASCP is

• OPM is fully integrated with ASCP to perform
  material and resource planning using process
  features such as
• Recipes/Validity Rules
• On hand lot expirations
• By-products, Co-products
• Scaling
• MTQ

124
OPM Integrates with APS

• Integrated APS products with OPM
• ASCP
• Demand Planning
• Manufacturing Scheduling
• Inventory Optimization
• Collaborative Planning

125
OPM MRP
126
New Features for OPM PMRP

• Considers lot expiration
• Auto release suggestions

127
MRP Material Inquiry showing the expired lot as a
negative supply (reducing on-hand to 25)
128
New Concurrent Program to Release MRP suggestions
129
OPM with ASCP
130
New Features for OPM with ASCP

• Production Execution enhancements
• Detailed feedback into batches
• Preferred effectivity in batch creation
• Firm flag on batch
• OPM enhancements in ASCP
• Shift simulation
• Resource exception messages
• Bottleneck resources
• Auto release of suggestions
• In-line forecast consumption
• Targeted resource availability

131
Detailed Feedback into Batches

• ASCP operation times dates update OPM batches

Planning
Shop Floor
Execution
132
Preferred Effectivity in Batch Creation

• Create the batch with the Recipe/Validity rule
  selected in ASCP

133
Preferred Effectivity in Batch Creation Feature
Overview

• OPM APS New Batch Displays the Effectivity used
  during planning by ASCP
• Create batch using selected recipe or change it

Selected Effectivity
134
Firm Flag on Batch

• Firming a batch prevents rescheduling by ASCP

135
Shift Simulation

• What-if capacity changes can be modeled

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Resource Exception Messages

• Over under loaded resource exceptions display
  in the ASCP workbench

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Bottleneck Resources

• ASCP will constrain only bottleneck resources

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Auto Release of Suggestions Full Auto Release

• Mass release check Production box on plan

Mass release option
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Auto Release of Suggestions Semi-Auto/Manual
Release

• Workbench release check suggestions
• Profile GMPAuto Implement APS suggestions (YES)

Release selected suggestions
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Auto Release of Suggestions Semi-Auto Release

• Enter criteria to create batches
• Profile GMPAuto Implement APS suggestions (OFF)

Enter Parameters
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In-line Forecast Consumption

• Forecast consumption now performed in the APS
  engine enabling
• Full use of Inventory Optimization
• Net Change capability with OPM.

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Targeted Resource

• Update resource calendar availability

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Process Execution
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New Feature Highlights
Process Execution

• Resource Back Flushing
• Support for Shop Calendar setups
• Terminate Production Batch

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Resource Backflushing
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Definition Backflushing

• Reducing the ingredient based on standard
  formula/routing and the finished goods completed

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Resource BackflushingFeature Overview

• Incremental Backflushing can now be used to
  backflush resource usage in addition to material
  usage

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ShopCalendar
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Support for Shop CalendarFeature Overview

• Shop Calendar respected in batch creation and
  rescheduling
• Warning if creating a batch to start during
  non-working time
• Calculation of batch duration takes into account
  non-working time
• Option to schedule batch during planned down time
  for overtime

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Terminate Batch
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Terminate BatchFeature Overview

• Ability to terminate a WIP batch
• Cancels remaining Pending steps
• Sets batch status to Completed and sets new
  Terminated indicator
• Leaves actual quantities as recorded to that
  point, but can be adjusted

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Process Costing
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New Features of Lot Costing

• Track lot cost of raw materials
• Merge lot cost (multiple receipts of same lot)
• Roll up manufactured lot cost
• Lot Cost History Report
• Stand-alone Patch

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Lot Level Costing
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Process Logistics
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New Feature Highlights
Process Logistics

• Reservation Against Production Workflow
• Multi-Lot Receipt
• Control on Customer Returns
• Auto Allocation Enhancements (Shipment)

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Reserving Against Production
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Reserve Production for Sales Order

• Allows sales order reservations against a
  Production Batch or Firm Planned Order (FPO)

Reservation converted to inventory allocation
Complete Batch
Create Reservation
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Reserving Against Process Execution Description

• Reserve against Pending and WIP Batches
• Reserve against Firm Planned Orders (FPOs)
• Batch completion converts reservations into
  allocations
• FPO reservations convert into batch reservations
• Customer Service and Production monitor and
  modify reservations

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Reserving Against Process Execution Reservation
Rules Setup

• (N) Production Supervisor gt Sales Order
  Reservations

Time period for which to display batches and FPOs
Allocation Priority for over-allocation
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Reserving Against Process Execution How to Use
this Feature

• Create sales orders
• Reserve Production to the order
• Convert the Firm Planned Order to a Batch
• Reservations are converted to batch reservations
• Manage changes between sales order and batch
• Complete the batch
• Pick confirm and ship the sales order

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Reserving Against Process Execution Reserve
Production

• (N) Order Management gt Orders gt Sales Orders

This tab shows batches and FPOs that can be
reserved
User enters reserved quantities
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Reserving Against Process Execution Convert FPO
to a Batch

• FPO Reservation is converted to a batch
  reservation
• FPOs can convert into one or more batches

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Reserving Against Process Execution Monitor
Reservations

• (N) Production Supervisor gt Sales Order
  Reservations

Find reservations based on sales order or batch
Modify reserved quantity, if needed
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Multiple Lot Receiving
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Receiving Multiple LotsDescription

• Quick entry of multiple lots in Receiving
• Uses automatic lot number generation
• Typing aid for users who receive many lots
  against one Receiving line

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Customer Returns
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Controlling Customer ReturnsDescription

• Validate lots and sublots for a return
• Control level of validation required
• Integrates with receipt recorded in Purchasing

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Automatic Allocation
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Automatic Allocation Enhancements Description

• Match against quality specifications
• Allocation rules include use of QC specifications
• Uses quality data maintained in OPM Quality
• Customer specification matched against lot
  results
• New user interface to run automatic allocation
• Accepts parameters to determine inventory
• Allows allocation for multiple delivery lines
• Handles allocation of inventory after pick release

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Agenda

• Process Manufacturing
• OPM Positioning
• Introduction to OPM
• 11.5.10 Enhancements
• Future Direction
• Questions and Answers

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Beyond 11i.10

• Inventory Convergence
• Enhance Core Process Modules (Formulation
  Management, Production, Quality,Costing)
• Campaign management
• Attribute driven manufacturing
• Outsourced manufacturing
• Define Process Industries Requirements
• Product Life Cycle Management
• Inventory / Logistics / Transportation
• Planning

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A