MFG WIP Advisor Webcast 2013 1204

1
Copyright 2013, Oracle and/or its affiliates. All rights reserved.
Oracle Advisor Webcast Program
Current schedule
Archived recordings
Doc ID 740966.1
Future Advisor Webcasts

Upcoming live webcasts and recent recordings:
VOICE STREAMING ENABLED
Teleconference Access:
US & Canada: 866- 627-3315
Toll Number: +1-706-758-7972
Global Toll-Free: 1148600.1
Password: Oracle FLOW
WIP Webcast Calendar/Archive
Doc ID 1319827.1
All Webcast Calendar/Archive
Doc ID 740966.1
What advisor webcast topics do YOU want to see presented? Visit the Work
In Process and Flow Manufacturing My Oracle Support Community today to
let us know.
Safe Harbor Statement

The following is intended to outline our general product
direction. It is intended for information purposes only, and
may not be incorporated into any contract. It is not a
commitment to deliver any material, code, or functionality,
and should not be relied upon in making purchasing decision.
The development, release, and timing of any features or
functionality described for Oracles products remains at the
sole discretion of Oracle.
Oracle Advisor Webcast

Flow Manufacturing: An End to End Flow
Zar Ahmed
Objectives
To understand the basic
concepts of Flow
Manufacturing (FLM)
Explain the required setups
To provide details of the
basic process flow of FLM
Agenda
Overview
Basic Setup Steps
Process Flow using screenshot demo
Basic Technical Details APIs, Tables.
Q&A
Overview
FLM (also called LEAN Manufacturing) is a manufacturing
approach that aligns production with customer demand.FLM

employs Just-In-Time (JIT) concepts such as :
Manufacturing to demand (vs. forecast),
Production lines for families of products (vs. process
layout),
Pull material using kanbans (vs. push material),
Backflush material and costs upon completion (vs. at each
operation), and so on.
8
Overview
Key principles of FLM are :
Decrease Inventory.
Eliminate waste the more stocking points you create, increases waste.
Continuous Production Line concept : so if you need to store your products before they
come off the production line, it is not really FLM. No idle resources.
FLM products repetitive tasks, same product produced (in discrete mfg, products can be
more tailored to specific customer needs).
Optimize machine utilization
Reduce response time to customer needs
Simplify shop floor activities.
Production without use of work orders.
Only one final product typically produced on the line.
Raw Materials and sub-assemblies are added at different operations.
Lower skill levels typically then in discrete manufacturing.
Long production lines mean lower costs.
Mixed-Mode Execution
Complete Manufacturing Operations Management
Mobile Supply Chain Applications
Discrete and Process Mfg
Flow
Manufacturing
Shop Floor
Management
Make to order demand flow

technology or lean mfg lines
or cells in a low-to-medium
production volume, high
product mix environment
Lot / serial controlled end

items that require lot integrity
during entire production cycle.
Low volume desktop / high
volume interface requirement
plus
Oracle MES / MOC

Best for
Traditional manufacturers
in a low-to-medium
production volume, high
product mix environment
Flexible and
Configurable
Manufacturing
Execution
Capabilities
10
Production
Assembly
Configurable work lists

Paperless work instructions via graphically rich screens
Streamlined transactions
Supervisor dashboard to monitor shop floor state
Integrated quality data collection
Product genealogy tracking
Label printing (product identifiers, packaging, etc)
Oracle Flow Manufacturing Solution

Accurately Plan and
Capture Demand
Holistic planning with consensus forecasting, multi-
Design for Balanced

Operations
Support for mixed model production, graphical tool
Schedule and
Sequence for
Efficient Production
Execute in Real-Time
with Built-In
Quality Management
Plan & Execute
Kanban Material
Movement
11
channel order capture with global ATP
for flow line design and balancing
User-definable scheduling and sequencing rules

with integrated feeder line and supplier sequencing
Intuitive UI for paperless work instructions, built-in

quality management and reporting
Complete Kanban management with pull

sequencing, Kanban planning and execution
Flow Manufacturing Definition

Who is it For?
Demand-driven manufacturers in any industry
What Problems Does it Solve?

Lack of formalized, sustainable
lean processes
Lack of Lean Mfg integration
with core ERP data
(e.g., cost accounting and
order management)
What Does it Do?
Framework to document flow mfg processes

Simulates and calculates flow line design
Designs material replenishment processes
Sequences demand directly to production line
Simulates daily demand for resource planning
Provides line performance metrics
Benefits:
Lean processes that are sustainable and repeatable on a global scale
Speeds the introduction of new products to the Flow Mfg process
Supports continuous improvement in manufacturing processes
Integrated software that directly supports lean mfg / lean supply chain mgmt
12
REQUIRED SETUPS
13
Summary of Setups
1.
2.
3.
4.
5.
6.
14
Define your items.

Define your flow lines. These are manufacturing work areas where you produce a flow
assembly. Can manufacture multiple items on a flow line simultaneously. Flow lines specify
your resources and departments.
Product Synchronization : Define the products Process Flow using Flow Routings .Specify
the processes and activities (events) and the line operations). Use Graphical Designer
Workbench for this.
Balance Flow Lines (balance resources and events) : Mixed Model Workbench is the tool
used to do this. Calculates process times and required resources to do this.
Create Pull Sequences for every item : FLM uses Kanban replenishment system to signal
material requirements and pull material from demand sources.
Pull Sequence = definition of the item, where it is used and where it is supplied.
Setup Kanban Planning. Graphical Kanban Workbench : Kanban setup , Kanban planning,
define pull sequences, planning simulation , kanban transactions.
Summary of Setups
Define Scheduling rules : Purpose of line scheduling is to synchronise production with
customer demand. Use Line Scheduling Workbench to achieve this.
Define the scheduling rules that will be used for this.
8. Setup Sequencing Constraints : Sequencing is used to consider your demands and
determine a sequence for building assembly items
9. Setup Flow Execution Workstation : This is used to meet daily production requirements
(flow line transactions, track work flow, complete assemblies, view component and
resource information.
10. Enable profile FLM : Enable Flow Sequencing.
7.
15
Setup 1:Define Your Items
16
Setup 1:Optional : Product Families
17
Setup 2 : Define Flow Lines

.Mfg Work Area where the assembly is produced.
18
Setup 3 : Product Synchronization

Define a Flow Routing
19

Add Events, processes and Line operations
20

Events : Detailed Work Content of the Line
21

Processes : Optional. Discrete Grouping of the Events
Used to look at balance of the shop using MMW before moving to flow
22

Operations : Grouping events into your line workstations.
23
Setup 4 : Balance Flow Lines (MMW)

Line Balancing : Process of defining balanced production lines by including products made, operations
performed and materials and resources consumed at each step.
The idea of line balancing is simply to meet the required demand in the quickest time possible.
MMW : Used to balance lines against specific demand and calculate process volume, machine and labor
requirements, TAKT times and in-process-kanban (IPK) requirements.
TAKT = rate at which products must be produced to meet schedules.
24
Setup 4 : Balance Flow Lines (MMW)

Amend assignments; simulate ; balance.
Actions used to balance lines include : reduce or remove non-value added work, grouping the work into
smaller or larger units, increasing resource, increasing in-process inventory, adding additional lines.
25
Line Design and Balancing

Simplify Production Modeling
Define processes
Define and associate processes with product

families, items, or configurable models
Model primary & alternate

production paths
Link operations together as primary, feeder and /

or rework processes
Assign work
content times
For each process, create a detailed sequence of

events, or estimate time
Share processes & events

between assemblies
Define standard processes and standard events,

or common product family synchronizations
Perform mixed
model calculations
Balance line
26
Graphical
Line Designer
Calculate line and operation takt, and reqd

resources; highlight imbalances
Define balanced operations, add IPKs,
add resources
Mixed-Model Map
Workbench
Setup 5 : KANBAN SETUP
27
Setup 5 : Define Pull Sequences

Pull Replenishment : To signal Material requirements.
28
Setup 6 :Kanban Setup Define and Launch Plan

Define your plan
Launch Plan creates the Kanban cards based on parameters
Auto-trigger pull demand, pick requests & start / completion labels
29
Setup Step 6 :Update Production

Update production to reflect changes in production plan and kanban cards
30
Setup Step 6 :Kanban Cards

Kanban Card a signal that there is a product shortage
Click Replenish to replenish the component.
31
Integrated Kanban Management

Improve Inventory Turns and Labor Efficiency
Point of Supply
Inventory
Production
Supplier
Feeder Plant
Pull
Flexible Pull Sequence
definition supporting single
card, dual card, and nonreplenishable kanbans
32
Signal via electronic visual cues
Pull
Sequence
Kanban
Planning
Point of Use
Mfg / Assembly
Floor Stock
Kanban
Execution
Plan
Simulate and compare multiple
demand scenarios
Generate new Kanban cards and

automatically cancel outdated cards
Staging Zone
Execute
Automatically create supporting
transactions (PO, Flow
Schedule, Move order)
Setup 6 : Component Pick Release (option)

FML uses Kanban for Component replenishment.
Can use CPR for slow moving or randomly used components as
alternative.
33
Setup 7: Define Scheduling Rules

Used by Line Scheduling Workbench (see later).
34
Setup 8 : Setup Sequencing Constraints
35
Sequencing is used to consider your demands and determine a sequence for building assembly items. Define attributes and constraints and build
them into rules for the assigned production line.
Attribute = characteristic of your demand
Constraint = restriction enforced on an attribute. E.g Colour. Red first and then black. Sequence assemblies based on this.
Rule = grouping of prioritized constraints for the attributes.
Setup 9 : Setup Flow Exec Workstation
36
Sequencing attributes, sequencing rules.

Assign the sequencing rule to the production line
Define the workstation parameters /preferences for look and feel and for available options
HTML and Forms versions of Flow Workstation exist. We will focus on HTML version.
PROCESS FLOW : 1 : Demand

Sales orders and/or Planned Orders from ASCP. SO : 66646 created.
37
PROCESS FLOW : 2 : Create Flow Schedules

Open the Line Scheduling Workbench ; Enter criteria, Create Flow schedules.
38

Flow Schedules have been created. Click Details.
39

Note the individual flow schedules and the link to SO 66646.
The flow schedules take into account the sequencing rules/constraints
40

Can check component availability against the flow schedule lines.
41
42
Sequencing tasks can be used to create flow schedules also

A concurrent program creates the flow schedules on submit.
Uses the defined sequencing rules and constraints
Options : Resequence existing schedules or create new schedules
PROCESS FLOW : 3 : Initialize Workstation

Select org, line and op and specify any optional selection criteria
Note : This assembly has 5 line ops : MBRD, CASE, DRV, TEST, PACK
43
PROCESS FLOW : 4 : View Schedules

Schedules can be seen in work queue mode as below or user entry mode
(scanned or entered). Controlled by the preferences defined.
44
PROCESS FLOW : 4 : View Schedule Details A

Drill into Schedule Number to see details - events tab shown below.
45
PROCESS FLOW : 4 : View Schedule Details B

Click on Event Seq Number to see the event details..
46
PROCESS FLOW : 4 : View Schedule Details C

Drilling into Events also shows detailed instructions, diagrams.
47
PROCESS FLOW : 4 : View Schedule Details D

Instructions tab shown below.
Details of instructions, diagrams, specifications etc
48
PROCESS FLOW : 4 : View Schedule Details E

Components tab shown below. Shows components for all the ops events.
49
PROCESS FLOW : 4 : View Schedule Details F

Resource Tab shows resources linked to the events for this line
operation and schedule.
50
PROCESS FLOW : 4 : View Schedule Details G

General details for the line schedule
51
PROCESS FLOW : 4 : View Schedule Details H

View any custom parameters used for the line schedule.
52
PROCESS FLOW : 5 : Update Schedule

Update any details if required.
53
PROCESS FLOW : 6 : Complete Line Operation

Click on Express Complete Line Operation Button for flow schedule
DJ877265, op MBRD (1st op)
54

This line op requires some mandatory quality data to be updated first.
Mandatory quality collection data can be specified for any op
55

Enter the quality data where required.
56

Now click on apply after quality data entered.
57

Note the completion message and the updated work queue.
The assembly has been moved to the NEXT operation. NO material transactions occur.
When you complete the LAST operation, you have option to complete the schedule.
58

To see impact of the op completion, query the next OP - CASE.
59

The assembly has been moved to the next op as can be seen.
Note : can set parameters to display different buttons for each op
60
PROCESS FLOW : 7 : Process All Operations

Complete Line op CASE moves assembly to Op DRV.
61

Complete Line op DRV moves assembly to Op TEST.
62

Complete Line op TEST moves assembly to final Op PACK.
63
PROCESS FLOW : 8 : Complete Schedule

There are 2 options for Assembly Completion :
- Complete Schedule : Info or review required (html version of work orderless completion)
- Express Complete Schedule: Automatic completion using defaults
64

Stage 1 :Select complete schedule option.
Options to amend qty and specify alternate routings at this stage.
65
66
Stage 2 : Enter quality data and specify any lot and serial numbers for lot and serial control components.
Can subsitute, remove components. l removed some components for ease of use.

Stage 3 : Transaction completed on clicking finish.Components are
backflushed. Assembly completed into inventory. Flow Schedule is

removed from work queue. DJ877265 no longer seen here.
67

Can see the assembly completion transaction below.
68

Note that you can go to complete schedule directly for the flow schedule and not move the
assembly through all the operations.
69

Can use forms version of Workorder Less Completion also
70
PROCESS FLOW : 9 : Scrap Assemblies

Can add option to scrap assemblies via the parameters
This follows same process as work orderless completion
71
Technical Information:
Q1:
Is there a public api for completing flow schedules?
A1:
Insert records in MTL_TRANSACTIONS_INTERFACE and set transaction source to flow schedule.

Then run inventory manager to process the completion. Will mimic work orderless completion and backflush the
components.
Q2:
How do we display additional details for completing the work in the custom property region of Flow Execution
Workbench?
A2:
Use the following:

Package Name: FLM_EXECUTION_UTIL
Procedure Name : GET_ATTRIBUTES
Q3:
Is there an API to import Flow Routing, Standard Line Operations, Standard Events & Events Resources?
A3:
No. Enter manually or use dataloaders. There is an ER to create api for this:
Bug 5460084: CREATE RESOURCES, STD OPERATION, ROUTING EXTERNALLY USING API'S
72
Q4:
What table is used to store Flow schedules ?
A4:
WIP_FLOW_SCHEDULES.
Here are other important tables :
FLM_KANBAN_SUMMARY summary of kanbans
FLM_MMM_PLANS - Mixed Model Map Plans
FLM_MMM_LINES - Mixed Model Map Lines
FLM_MMM_OPERATIONS - Mixed Model Map Operations
FLM_SEQ_RULES Sequencing rules
MRP_AD_FLOW_SCHDS stores details about deleted wip flow schedules
73
Q5:
What apis are available for FLM?
A5:
There are 3 apis :

1. Custom Kanban Quantity Calculation API : used to calculate kanban size and qty
Package Name: MRP_CUSTOM_LINE_SCHEDULE

Procedure Name: CUSTOM_SCHEDULE
2. Custom Schedule API : for extending the available line scheduling algorithms.
Package Name: MRP_CUSTOM_LINE_SCHEDULE

Procedure Name: CUSTOM_SCHEDULE
3. Flow Schedule API : create, update, delete, retrieve, lock, schedule and unlink order lines of flow schedules.
Package Name: MRP_FLOW_SCHEDULE_PUB

Procedure Name: PROCESS_FLOW_SCHEDULE
74
Summary
What we covered today
Looked at concepts of FLM.
Looked at how to setup FLM.
Looked at the basic process flow
using screenshots.
Considered basic apis and tables.
75
Flow / Lean
ETO
ATO / CTO
MTS
Standard
Lot-Based
Discrete
Repetitive
Flow Manufacturing
Support Lean Practices to Reduce Cycle Time & Waste
Value
Stream
Mapping
Line
Design
Lean
Planning
Lean
Execution
Define and associate
Calculate line and
Kanban planning
Kanban execution
Constrained based line
standard processes w/
configurable models
Add alternate paths

and rework loops
Add standard events,

associate with options
Identify TQC and
operation takt and

required resources
Highlight imbalances
based on options
planning percentages
Reorganize events into

balanced operations
value-add events
Associate work
instructions with
optional events
76
based on option
planning percentages
Demand leveling and

smoothing by line rate
Order promising by
line rate
Collaborative planning
for VMI and consigned
Inventory optimization
for postponement
sequencing based on
configuration and its
attributes
Feeder line & supplier

synchronization for
just-in-time configured
component delivery
Operator workstation to
deliver configured work
instructions to the floor
To ask a question on the

phone line, select *1 on
your phone.
To ask a question online,

use the Q&A area at the
top.
Your question will be read

aloud in the order
received.
Question can also be

asked on the My Oracle
Support Communities
Questions & Answers
77
Top Articles and Community Links

Work In Process Information Center [ID
1417725.2].
Work In Process & Flow Manufacturing
Advisor Webcast Calendar And Archive [ID
1319827.1]
All Advisor Webcasts [ID 1455888.1].
Continue the Discussion on the Work In
Process & Flow Manufacturing My Oracle
Support Community.
78
My Oracle Support Community

Collaborate with a large network of your industry peers, support professionals, and Oracle
experts to exchange information, ask questions & get answers.
Visit the My Oracle Support
Community now!!
1.
Log into My Oracle Support.
2.
Select the Community tab.
3.
Start typing the community

name in the Find a
Community Quick Find field.
79
Advisor Webcast Program

Register for upcoming live advisor
webcasts.
Access past webcast recordings
and presentation material.
Continue the discussion on a
specific webcast topic.
Let us know what topics you would
like presented in the communities or
in the post webcast survey.
Doc Id 740966.1
80
Learn More
Available References and Resources to Get Proactive
About Oracle Support Best Practices

www.oracle.com/goto/proactivesupport
Get Proactive in My Oracle Support
https://support. oracle.com | Doc ID: 432.1
Get Proactive Blog
https://blogs.oracle.com/getproactive/
Ask the Get Proactive Team
get-proactive_ww@oracle.com
81
THANK YOU
82
83

MFG WIP Advisor Webcast 2013 1204

Загружено:

Сведения о документе

Оригинальное название

Авторское право

Доступные форматы

Поделиться этим документом

Поделиться или встроить документ

Параметры публикации

Этот документ был вам полезен?

Это неприемлемый материал?

Авторское право:

Доступные форматы

MFG WIP Advisor Webcast 2013 1204

Загружено:

Авторское право:

Доступные форматы

1

Copyright 2013, Oracle and/or its affiliates. All rights reserved.

Oracle Advisor Webcast Program

Copyright 2013, Oracle and/or its affiliates. All rights reserved.

Future Advisor Webcasts

Copyright 2013, Oracle and/or its affiliates. All rights reserved.

Safe Harbor Statement

Copyright 2013, Oracle and/or its affiliates. All rights reserved.

Oracle Advisor Webcast

Copyright 2013, Oracle and/or its affiliates. All rights reserved.

Copyright 2013, Oracle and/or its affiliates. All rights reserved.

approach that aligns production with customer demand.FLM

Copyright 2013, Oracle and/or its affiliates. All rights reserved.

Copyright 2013, Oracle and/or its affiliates. All rights reserved.

Make to order demand flow

Lot / serial controlled end

Oracle MES / MOC

Copyright 2013, Oracle and/or its affiliates. All rights reserved.

Configurable work lists

Oracle Flow Manufacturing Solution

Holistic planning with consensus forecasting, multi-

Design for Balanced

Support for mixed model production, graphical tool

Copyright 2013, Oracle and/or its affiliates. All rights reserved.

channel order capture with global ATP

for flow line design and balancing

User-definable scheduling and sequencing rules

Intuitive UI for paperless work instructions, built-in

Complete Kanban management with pull

Flow Manufacturing Definition

Demand-driven manufacturers in any industry

What Problems Does it Solve?

What Does it Do?

Framework to document flow mfg processes

Copyright 2013, Oracle and/or its affiliates. All rights reserved.

Copyright 2013, Oracle and/or its affiliates. All rights reserved.

Define your items.

Copyright 2013, Oracle and/or its affiliates. All rights reserved.

Copyright 2013, Oracle and/or its affiliates. All rights reserved.

Setup 1:Define Your Items

Copyright 2013, Oracle and/or its affiliates. All rights reserved.

Setup 1:Optional : Product Families

Copyright 2013, Oracle and/or its affiliates. All rights reserved.

Setup 2 : Define Flow Lines

Copyright 2013, Oracle and/or its affiliates. All rights reserved.

Setup 3 : Product Synchronization

Copyright 2013, Oracle and/or its affiliates. All rights reserved.

Setup 3 : Product Synchronization

Copyright 2013, Oracle and/or its affiliates. All rights reserved.

Setup 3 : Product Synchronization

Copyright 2013, Oracle and/or its affiliates. All rights reserved.

Setup 3 : Product Synchronization

Copyright 2013, Oracle and/or its affiliates. All rights reserved.

Setup 3 : Product Synchronization

Copyright 2013, Oracle and/or its affiliates. All rights reserved.

Setup 4 : Balance Flow Lines (MMW)

TAKT = rate at which products must be produced to meet schedules.

Copyright 2013, Oracle and/or its affiliates. All rights reserved.

Setup 4 : Balance Flow Lines (MMW)

Copyright 2013, Oracle and/or its affiliates. All rights reserved.

Line Design and Balancing

Define and associate processes with product

Model primary & alternate