Oracle Applications 11i

Bill of Materials

Introduction
Overview

of Bill of Material

Oracle Manufacturing and Oracle Order Management use bills of material to store lists of items that are associated with a parent item and information about how each item is related to its parent. Oracle Manufacturing supports standard, model, option class, and planning bills of material. Can create either an engineering or manufacturing bill, copy an existing bill, or

Bill of Material
BOM Item

Sub Assembly1

Phantom Sub Assembly

Component1

Component2

SubComponent1

SubComponent

SubComponent1

SubComponent

Product integration
Oracle

Bills of Material integrates with the following applications

Oracle Inventory Oracle Engineering Oracle Work in Process Oracle Purchasing Oracle Master Scheduling/MRP and Oracle Supply Chain Planning Oracle Order Entry

Bill of Material Types

Standard

Model
Option

Class Planning Engineering Phantom

Bill of Material Types (Contd.)

Standard : A standard bill of material is the most common type of bill and lists the mandatory components, the required quantity of each component, and information to control work in process, material planning, and other Oracle Manufacturing functions. Model : A model bill of material defines the list of options and option classes you can choose in Oracle Order Management to order a configuration. Planning : A planning bill of material is a bill of material structure that includes a percentage

Navigation Bill of materials

Bill of materials

Bills

Bills

Main page
BOM Item Various tabs available

Components Choose buttons to perform related tasks: Substitutes :- Assign substitute components Designators :- Create reference designators Bill Details :- Reference common bills Revision :- Define item revisions

Components

Bills of Material restricts the types of items you can assign as components based on the type of bill you are defining. Parent BOM Item Component BOM Valid Parent/Component Relationships Type Item Type Standard Item Model Item Standard Item Standard Item, Model Item, Option Class Item Option Class Item Standard Item, Model Item, Option Class Item

Revisions
Can

define any number of revisions for the item Revisions are sorted according to ASCII rules. Therefore, cannot use revision 10 after revision 9 because, according to ASCII sorting, 10 precedes 9.

Revisions (Contd.)

List all the Revisions for BOM Item.

Substitute Component

Substitute Component. E.g. A 40GB HDD can be substituted by a 60 GB HDD

Reference Designators
The warning indicates that the reference designators cannot exceed the component quantity. If qty related check box is unchecked then the designators can exceed component quantity.

Reference designators are sequenced comments and instructions that pertain to a component.

Alternate Bills
Alternate field is used to create alternate bills

Copying Bill Information

You

can save time defining new, similar bills by copying their information rather than creating them manually. You can copy a bill from your current organization or from another organization that shares your same item master organization. You can then modify your new bill as necessary. You can copy any revision of a primary

Copying Bill Information (Contd.)

Tools Copy Bill from. To copy from existing bill

Copying Bill Information (Contd.)

Organization where bill exists

Select Item whose bill is to be copied

Copying Bill Information (Contd.)

The following message is displayed when copy button is pressed.

Copying Bill Information (Contd.)

The components, substitutes, designators etc are copied for this bill.

Common Bills of Material

If

two or more organizations manufacture the same item using the same bill of material, you can define the bill in one organization and reference it from the other organizations. You cannot reference another bill or routing as a common if that bill or routing also references a common. In other words, you cannot create a chain of common references.

Common Bills of Material (Contd.) Tools Create

common bills

Common Bills of Material Single Organization: Enter the organization and item names where the common bi (Contd.) needs to be created.

Organization Hierarchy: Enter the required name of the organization hierarchy. In this case, the processing is done for all organizations below the current organization in the chosen organization hierarchy. All Organizations: Then processing is done for all organizations that have the same item master organization as the current organization.

Common Bills of Material (Contd.)

When clicked on OK a request is submitted. The status of common BOM creation can be seen from view log of concurrent request.

Practice
Create

a BOM. Add components and other necessary details for BOM. Create Substitute components and Reference Designators. Create a new BOM by copying an existing BOM Create an alternate BOM for an item in an organization. Enable an item in a second organization and copy a BOM from the first

Routings

Introduction
routing defines the stepbystep operations you perform to manufacture a product. Each routing can have any number of operations. For each operation specify a department that determines the resources you may use for that operation. Routings are used to specify the
A

Primary and Alternate Routings

A

primary routing is the list of operations most frequently performed to build a product. When you define a new primary routing, you specify only the item (no alternate name) and you can assign a routing revision. You can define one primary routing and many alternate routings for an item. You can define an alternate routing to

Dynamic Routing
Paths

that jobs take are not always known at creation. Depending on initial operations and their results, operation flexibility is frequently required. There can be numerous possibilities defined as part of a routing network, any one of them being selectable based on the outcome of the last operation, E.g. A Chemical product that undergoes some chemical reaction.

Creating a Routing
For

each routing, define the operations, the sequence to perform them, and the resources required at each operation. You can define either a primary or an alternate routing You must define at least one department before you can create a routing BOM Allowed must be set to Yes for the item you are creating a routing

Overview (Contd.)
are anything except component material used to manufacture, cost, or schedule products. A department is a collection of resources designed to perform certain tasks. A department class is a collection of departments.
Resources

Overview (Contd.)
Department
Department Class - Production Department Class

Department: Machining Shift 1 Machinist Shift 2 Shift 1 Drill Press Shift 2

Department: Welding

Welder

Shift 1

Welding Torch

Shift 1

Resources

Creating a Department Class

Departments button display the departments assigned to this department class and the dates when these departments can no longer be assigned to routing operations. Navigation Setup Department Classes

Department classes are used to group departments for shop floor scheduling and control, and to identify manufacturing cells and flexible machine centers. Department classes are used for reporting purposes.

Defining a Department
A

department is an area within your organization that consists of one or more people, machines, or suppliers, where you want to collect costs, apply overhead, and compare load to capacity. You assign a department to each operation in a routing, and assign resources that are available for that department.

Defining a Department (Contd.)

Defining a Department (Contd.)

Each resource can be assigned to any number of departments; multiple resources can be assigned to each department. Enter the number of capacity units (resource units) available for this department, for example, the number of machines for a machine resource.

For owned resources, indicate whether this department can share the resource and capacity with other departments.

Click Resources button on the Departments page

Defining a Resource
Use

resources to define the time an assembly spends at an operation and the cost you incur at the operation. A resource is anything you require to perform, schedule, or cost, including but not limited to employees, machines, outside processing services, and physical space. A resource and usage rate for all scheduled activities is required in a

Defining a Resource (Contd.)

Bills of Material Routings Define Resources

Defining a Resource (Contd.)

You can define the roles which represent what an employee can do for a required task.
Click on the Employees Button in Resources window

Creating a Routing
Bills of material

Routings

Routings

Organization code

Creating a Routing (Contd.)

Item for which routing is to be created Populate for alternate routing

Department name

Operation sequence number

Assigning Operation Resources

Resource name
Item: When charges fluctuate with quantity change. Lot : When resource usage quantity is the amount required per job or schedule

Assigning Operation Resources (Contd.)

Two or more resources can be scheduled to be working concurrently within the same job operation

Assigning Operation Resources (Contd.)

Determine how each resource is charged in Work in Process. You can charge resources manually or automatically

Assigning Operation Resources - Alternate

Optionally, you can define substitute resources for each primary resource group defined. This enables you to specify resource sequences that can replace the primary resource group

Creating Routing Revision

The implementation date, which is either the date the revision was added or the date the routing was transferred from Oracle Engineering, is displayed. If the routing is transferred from Engineering, the ECO text is displayed

Routing Details

Completion Subinventory and Locator can be entered here.

Creating Custom Deletion Constraints

Navigation Bill of Materials Setup Delete Constraint

Use custom deletion constraints to enforce specific business rules. Custom deletion constraints prevent the deletion of bills or routings if your data meets the conditions set forth in the constraint.

Lead Time

Lead Time Definitions

Fixed

LeadTime

Fixed Leadtime is the portion of leadtime that is independent of order quantity. This could be setups, teardown, batch processes or anything else that requires time to do a lot. Fixed leadtimes for an item can be entered manually. A manually entered leadtime will be replaced by the leadtimes generated by the Manufacturing Leadtime rollup

Variable

LeadTime

Lead Time Definitions (Contd.)

PRE-PROCESSING

LEADTIME

Pre-Processing Leadtime is the time required to release a purchase order. It is used for Purchase orders, discrete jobs and repetitive lines. It can include the requisition processing and any approval cycles required. It can also be used for the time necessary to create internal paperwork for a discrete job or repetitive line from the time you learn of the requirement.

Lead Time Definitions (Contd.)

CUMULATIVE

MANUFACTURING

LEADTIME

Cumulative Manufacturing Leadtime is the time required to make an assembly if all raw materials are in stock. This assumes that you must manufacture every assembly, level by level. BOM automatically calculates this value.

CUMULATIVE

TOTAL LEADTIME

CUMULATIVE TOTAL LEADTIME is the time required to make an assembly if no raw

LeadTime Definitions (Contd.)

Inventory

Item

Organization Item

Cost Rollup

This-Level and Previous-Level Costing

Oracle Cost Management (OCM) uses thislevel and previous-level costing concepts. This-level costs are the routing costs of the assembly. Previous-level costs are the component costs of the assembly, including the routing costs of those components
This-level costs = Routing costs Previous-level costs = Component costs

This-Level and Previous-Level Costing (Contd.)

This-Level

Costs

The outside processing, resource, and overhead costs at the current level of an assembly Any material overheads earned upon completion of an assembly

Previous-Level

Costs

The material, material overhead, outside processing, resource, and overhead costs of the components used in the manufacture of an assembly

Single-Level Versus Full Cost Rollup

Item: Bicycle Single-level rollup: 110.00 Full cost rollup: 120.00 Item: Wheel QPA: 2 Cost: 10.00 (old) Cost: 15.00 (new) Item: Frame assembly QPA: 1 Cost: 80.00 Full cost rollup: 90.00

Item: Handlebar QPA: 1 Cost: 20.00 (old) Cost: 30.00 (new)

Item: Frame QPA: 1 Cost: 50.00

Item: Seat QPA: 1 Cost: 10.00

Single-Level Versus Full Cost Rollup (Contd.)

Full

Cost Rollup

A full cost rollup first performs a bill of material explosion for the assemblies to determine the structure to the lowest level. It then builds the cost of the assemblies starting with the lowest level and works up the structure to the toplevel assembly. This method gives you the most current costs for your assemblies because it reflects the most current bill of material structure and component costs for your assemblies.

Single-Level Versus Full Cost Rollup (Contd.)

Single-Level

Cost Rollup

Use a single-level rollup to avoid rolling up costs at lower levels. A single-level rollup looks only at the first level of the bill structure of each assembly being rolled and then rolls the cost for the items at this-level into the parent. This method does not reflect structure or cost changes that have occurred at levels below the first level of your assemblies. Use single-level rollups to assign costs to new

BOM and Routing Open Interface - Bill of Materials

Interface Tables
BOM_BILL_OF_MTLS_INTERFACE

BOM_INVENTORY_COMPS_INTERFAC

E BOM_ASSY_COMMENTS_INTERFACE BOM_REF_DESGS_INTERFACE BOM_SUB_COMPS_INTERFACE MTL_ITEM_REVISIONS_INTERFACE

Interface Tables (Contd.)

In

order to import a BOM with components, you need to populate:

BOM_BILL_OF_MTLS_INTERFACE BOM_INVENTORY_COMPS_INTERFACE

If

you want to assign standard comments, reference designators, and substitute components to your BOM, you need to populate:

BOM_ASSY_COMMENTS_INTERFACE BOM_REF_DESGS_INTERFACE

BOM_BILL_OF_MTLS_INTERF ACE table

REQUIRED

COLUMNS FOR BOM_BILL_OF_MTLS_INTERFACE.

ASSEMBLY_ITEM_ID ORGANIZATION_ID ASSEMBLY_TYPE

BOM_BILL_OF_MTLS_INTERFAC E table (Contd.)

REQUIRED

COLUMNS FOR BOM_BILL_OF_MTLS_INTERFACE

ASSEMBLY_ITEM_ID ORGANIZATION_ID ASSEMBLY_TYPE PROCESS_FLAG

If

you create an alternate BOM, you must also enter a value in the ALTERNATE_BOM_DESIGNATOR column.

BOM_INVENTORY_COMPS_INTE RFACE table

REQUIRED

COLUMNS FOR BOM_INVENTORY_COMPS_INTERFAC E TABLE

PROCESS_FLAG COMPONENT_ITEM_ID COMPONENT_SEQUENCE_ID OPERATION_SEQ_NUM EFFECTIVITY_DATE BILL_SEQUENCE_ID

You

must also specify a value in the

BOM_ASSY_COMMENTS_INTER FACE table

REQUIRED

COLUMNS FOR THE BOM_ASSY_COMMENTS_INTERFACE TABLE.

STANDARD_REMARKS_DESIGNATOR BILL_SEQUENCE_ID PROCESS_FLAG

BOM_REF_DESGS_INTERFA CE table
REQUIRED

COLUMNS FOR BOM_REF_DESGS_INTERFACE TABLE.

COMPONENT_REFERENCE_DESIGNATOR COMPONENT_SEQUENCE_ID PROCESS_FLAG

You

can only import data into the BOM_REF_DESGS_INTERFACE table for standard components assigned to standard, model and option class BOMs.

BOM_SUBS_COMPS_INTERF ACE table

REQUIRED

COLUMNS FOR BOM_SUBS_COMPS_INTERFACE TABLE.

SUBSTITUTE_COMPONENT_ID SUBSTITUTE_ITEM_QUANTITY COMPONENT_SEQUENCE_ID PROCESS_FLAG

You

can only import data into the BOM_SUBS_COMPS_INTERFACE table for standard components assigned to

Import Rules
Different

values of PROCESS_FLAG are

All inserted rows must have the PROCESS_FLAG set to 1 (Pending) Import program validates records with PROCESS_FLAG 1. If the assign or validate procedure fails for a row, the program sets the PROCESS_FLAG to 3 (Assign/Validation Failed) If a row fails on import, the program assigns a value of 4 (Import Failed) to the PROCESS_FLAG Successfully imported rows have a

Tracking error record

To

identify the error message for a failed row, the program automatically populates MTL_INTERFACE_ERRORS table with the same value as the TRANSACTION_ID value. Each error has a value for the MESSAGE_NAME and REQUEST_ID columns in the error interface table.

MESSAGE_NAME column corresponds to messages stored in the Oracle Application

Interface Tables for Routings

BOM_OP_ROUTINGS_INTERFACE

BOM_OP_SEQUENCES_INTERFACE
BOM_OP_RESOURCES_INTERFACE BOM_OP_INSTRUCTIONS_INTERFACE MTL_RTG_ITEM_INTERFACE

Interface Tables (Contd.)

To

import a routing with operations and resources, you need to populate the following tables:

BOM_OP_ROUTINGS_INTERFACE BOM_OP_SEQUENCES_INTERFACE BOM_OP_RESOURCES_INTERFACE

If

you want to assign standard instructions to your routings, then you populate the BOM_OP_INSTRUCTIONS_INTERFACE table

BOM_OP_ROUTINGS_INTERF ACE table

REQUIRED

COLUMNS FOR THE BOM_OP_ROUTINGS_INTERFACE TABLE.

PROCESS_FLAG ASSEMBLY_ITEM_ID ORGANIZATION_ID ROUTING_TYPE

If

you are creating an alternate routing, you must also enter a value in the ALTERNATE_ROUTING_DESIGNATOR

BOM_OP_SEQUENCES_INTE RFACE table

REQUIRED

COLUMNS FOR THE BOM_OP_SEQUENCES_INTERFACE TABLE

PROCESS_FLAG ROUTING_SEQUENCE_ID OPERATION_SEQ_NUM DEPARTMENT_ID EFFECTIVITY_DATE

You

must also specify a value in the ALTERNATE_ROUTING_DESIGNATOR

BOM_OP_RESOURCES_INTE RFACE table

REQUIRED

COLUMNS FOR THE BOM_OP_RESOURCES_INTERFACE TABLE.

PROCESS_FLAG RESOURCE_SEQ_NUM RESOURCE_ID OPERATION_SEQUENCE_ID

You

must specify a value in the ALTERNATE_ROUTING_DESIGNATOR column if you assign resources to an

BOM_OP_INSTRUCTIONS_INTE RFACE table

REQUIRED

COLUMNS FOR THE BOM_OP_INSTRUCTIONS_INTERFACE TABLE.

OPERATION_SEQUENCE_ID OPERATION_DESCRIPTION_CODE PROCESS_FLAG

MTL_RTG_ITEM_REVS_INTE RFACE table

REQUIRED

COLUMNS FOR THE MTL_RTG_ITEM_REVS_INTERFACE TABLE.

PROCESS_REVISION ORGANIZATION_ID INVENTORY_ITEM_ID PROCESS_FLAG

Import Rules
Different

values of PROCESS_FLAG are

All inserted rows must have the PROCESS_FLAG set to 1 (Pending) Import program validates records with PROCESS_FLAG 1. If the assign or validate procedure fails for a row, the program sets the PROCESS_FLAG to 3 (Assign/Validation Failed) If a row fails on import, the program assigns a value of 4 (Import Failed) to the PROCESS_FLAG

Tracking error record

To

identify the error message for a failed row, the program automatically populates MTL_INTERFACE_ERRORS table with the same value as the TRANSACTION_ID value. Each error has a value for the MESSAGE_NAME and REQUEST_ID columns in the error interface table.

MESSAGE_NAME column corresponds to messages stored in the Oracle Application