Oracle Apps Manufacturing

Author & Distribution

Jagan Vidyala
Freelance Consultant and Corporate Trainer
ORACLE SCM / MFG / ASCP / EAM Suites
10 Yrs of experience in IT consulting in
addition to 18 Yrs of domain experience in
Manufacturing, Inventory, Global Procurement,
Sales & Marketing and Turnkey Project
execution.
jvidyala@gmail.com

+91-91774-77013

Overview
Warehouse Management

Processes of a Warehouse

Processes of Warehouse
Receiving: Receiving material and finished
goods.
Put away: Put away materials and
finished goods you receive.
Storage: Storage items within the
Warehouse.
Picking: Pick orders for manufacturing
and shipping.
Packing: Pack orders for shipping.
Shipping: Ship orders to customers.
Value added services: Manufacturing,
assembly, knitting, and labeling.

Warehouse Management

Supply Chain Inventory Management

Inbound
Logistics

Storage
and Facility
Mgt.

Mfg and
Value
added
Services

Outbound
Logistics

Reverse
Logistics

Supply Chain Inventory Mgmt

Components
Inbound Logistics: Includes receiving
directly into inventory, receipt inspections,
label printing, and rules-based directed put
away to storage or opportunistic cross
docking
Value Added Services: Includes labeling,
packing, and kitting
Outbound Logistics: Includes picking,
staging, packing, product consolidation,
loading, and shipping
Reverse Logistics: Includes product
returns, refurbishment, and recycling

Supply Chain Inventory Mgmt

Components
Storage and Facility Mgmt: In addition to
Oracle's suite of Mixed Mode
Manufacturing storage and facility mgmt
module, Warehouse Mgmt extends intraorganization replenishments, container
mgmt, storage space optimization, cycle
counting and physical inventory, and
physical warehouse mapping.

Additional Product Requirement

To use Warehouse Management, you must implement INV, PO,

BOM, and OM.
Inventory to setup items, Orgs, SI and Locators.
BOM to define resources people, and calendars.
OM and PO provide the basic shipping and receiving
capability on which Warehouse Management builds.

Warehouse Management Application Hierarchy

Warehouse Management

Material
Mgt.

Rules
Engine

LPNs
Lot, Split
Merge

Task
Mgt.

Mobile Supply Chain Applications

Oracle Mobile (RF) Technology
Existing: Oracle Manufacturing & Distribution Applications

BOM
Quality
WIP

Project
Mfg.

Order Mgt.

Purchasing

Shipping

Receiving

Inventory

Mobile Supply Chain Application

MSCA provides a mobile user interface for
existing inventory, receiving, manufacturing,
quality, and shipping transactions.
The mobile environment provides operators
with an alternate set of pages to perform the
transactions supported in these
environments.
Operators can use hand-held frequency
devices to perform transactions in both WHM
and MSCA.
WHM extends the capability available in
MSCA to encompass the demand placed on a
dynamic high-volume warehouse.

WHM - Features
WHM provides the following features in
addition to features provided in MSCA
Task management
Material tracking with LPNs
A configurable rules engine that enables
to create custom picking rules, put away
rules, and compliance labeling rules.
Advance inventory and material mgmt
including material status, lot, and serial
support.
WHM also is heavily integrated with, and
extends some of the current functionality
in manufacturing applications.

Inbound Logistics - Tasks

Receiving with or without ASNs
Receipt check-in
Quality control inspection
Bar code printing
Directed put-away and storage optimization
Opportunistic cross docking

Inventory, Storage, and

Facility Mgmt - Tasks

Container and license plate management

Subinventory configuration
Advanced locator definition
Kanban replenishment management
Move orders (intra-org transfers and issues)
LPN based WIP completions
Task dispatching
Material status control
Lot and serial genealogy and tracking
Visibility of inventory ownership
Cycle counting and physical inventory
Date coding and shelf life monitoring
ABC classification and analysis

Value Added Services - Tasks

Kitting and dekitting
Customer compliance labeling
Mixed-mode manufacturing

Outbound Logistics - Tasks

Wave picking
Pick methodologies
Dock assignments
Directed picking rules
Task dispatching and interleaving
Task monitoring through the Oracle
Warehouse Management Control Board
Cartonization and packing
Interface with compliance labeling system
Shipment stage, consolidation, and loading
Shipment verification and close

Reverse Logistics - Tasks

Return Material Authorization (RMA)
receiving
Return To Vendor (RTV)
Refurbishment and Recycling
Optionally, if Oracle Service and Oracle
Depot Repair, then use Warehouse Mgmt
as part of the refurbishment or recycling
process.

Inventory, WHM and MSCA

Capability

Inventory

Warehouse
Management

MSCA

LPN Management

No

Yes

No

Task Management

No

Yes

No

Counting

Yes

Yes

Yes

Rules

No

Yes

No

RFID

No

Yes

Yes

Label Printing

No

Yes

Yes

MSCA provides a streamlined radio frequency based interface for

core inventory, shipping, quality, WIP, and receiving capabilities.
Warehouse Mgmt extends these capabilities beyond the base
functionality Inventory and MSCA provide.

Inbound Logistics

Outbound Logistics

Outbound Logistics
WMS Control Board: Provides warehouse managers with
a real time snap shot of the warehouse, and enables
them to redistribute operators as needed. They can
monitor the progress of tasks as well as manually
dispatch tasks to operators.
Consolidation: WM enables operators to consolidate
partially filled containers into fewer and better-optimized
containers.
Dock Appointment for Trips: Managers can use
Warehouse Mgmt to schedule outbound carrier
appointments, dock door availability, and staging lane
usage within the warehouse.
Shipment Verification and close: Once operators pick and
load an order, the system automatically determines the
items and qualities to deduct from Inventory.

Value Added Services

Value Added Services

Kitting and De-kitting: Supports kit to stock(work
order-less completion)and kit to order Pick to order).
Mixed-Mode Manufacturing: Supports ATO, projectbased or ETO, discrete and repetitive or flow
manufacturing concurrently.
Manufacturing Component Picking: Supports picking
for WIP through the mobile user interface.
Manufacturing Assembly Completion and Put Away:
Supports WIP completion and put away through the
mobile user interface.
Manufacturing Quality Inspection: The statem
automatically generates material movement
transactions to move an item into the quality control
inspection area from manufacturing , based on options
defined during implementation.

Value Added Services

Product Compliance Labeling: Supports product
specific labels, based on rules defined.
Manufacturing Quality Inspection: The statement
automatically generates material movement
transactions to move an item into the quality control
inspection area from manufacturing , based on options
defined during implementation.
Integration with Project Manufacturing, Flow Mfg,and
Shop Floor Manufacturing: WM integrates with Project
Mgmt, Flow Mfg, and Floor Mgmt.
Integration with Project Manufacturing, Flow Mfg,and
Shop Floor Manufacturing: WM integrates with Project
Mgmt, Flow Mfg, and Floor Mgmt.

Storage and Facility Management

Mobile Application Architecture

License Plate Numbers (LPNs)

Nesting LPNs

LPN Context

Resides In Inventory
Resides in WIP
Resides in Receiving
Resides in In-transit
Issued out of Stores
Pre-generated
Packing
Picked
Defined but not Used
Resides at Vendor Site
Pre-pack for WIP
Loaded for Shipment

LPN Context

LPN Context

LPN Context

Material status

SI and Locator - Material status

Lot and Serial Attributes

Material Allocation

Allocation Decision Tree

Rules Setup

Define Rules
Define Strategies
Assign Strategies in Rules Workbench

Define Rules: Restriction

Define Rules: Sort Criteria

Define Rules: Default

Strategies

List of Rules
Different levels
Assign Strategies

Task Type, Label Format, and

Operation Plan Selection Rules

Are not assigned to strategies

Linked directly to an organization
Rule weight determines search order

Consistency Requirement

Rules Simulation
The rules Engine Simulator enables to
create and debug the picking and put away
processes.
Use the rules simulator for thefollowing:
Test individual rules
Test strategies
Test the rules process

RFID Technology
Unique identifiers
Associate identifiers with system records
Export events to Warehouse Management
Report Exceptions

Radio Frequency Devices

WHM Supports, two types of UIs
1. Telnet - telnet over TCP/IP
2. GUI - J2ME compatible Java virtual
machines

Labeling

Label Types

Label Types

Label Formats

Assigning Label Types to Business Flows

Print labels automatically as part of the

business flow
Associate a label type to more than one
flow

Receiving Flows or Routings

Subinventory Types

Locator - Types

Document based Receiving

Item based Receiving

Receiving Methods

Standard Routing Flow

Inspection Routing Receipt

Direct Receipt Flow

Express Receipt Routing

Express Receipts

Mixed Receipt Routing

Desktop vs. Mobile Receiving

Receive Inspection

Put away

Desktop

Desktop

Desktop

Desktop

Mobile

Mobile

Mobile

Desktop

Mobile

Material Resides in LPN

Mobile

Mobile

Mobile

Material Resides in LPN

Material is loose
Material Resides in LPN*

Mobile Receiving Option

Unavailable Mobile Receiving Option

LPN Receipts

Lot and Serial Receiving

Automated Matching of Received Material

Automated Matching of Received Material

Receiving - GTINs

GTIN - Setup

Quality vs. Purchasing Inspection

Standard Inspection

accepted material

Quality Inspection

accepted material

Inspection Storage Requirement

Returns

Responsibilities
Whse Mgmt Super User Vision Operations (USA)
Warehouse Manager
Whse Mgmt Mobile User Vision Operations (USA)
Whse Mgmt

Cost Groups

Cost Groups

System Assigned Cost Groups

System Assigned Cost Groups

Warehouse Mgmt assigns a cost group to inbound
material at receipt.
Set up rules to determine the appropriate cost
group based on item, item category, and supplier.
If the system does not find a appropriate cost
group it will assign default cost group of the SI
where the material is put away.
Cost groups are assigned by system when the
following transactions are performed
Material is put away in a storage locator
Material is cross docked
Any material movement in an operation plan
which is in inventory.

Cost Groups Setup

1.Define cost group for org
2.Define subinventory and
assign default cost group
3.Define cost group rules

4.Define cost group strategies

5.Assign strategies in rules
workbench

Commingling
The system prevents commingling of items when
cost group is the only distinguishing characteristic
between two quantities of loose inventory within a
single locator or LPN
Multiple cost groups of a single item may reside
within a single Locator or LPN as long as each cost
group is uniquely identifiable.

System Assigned Cost Groups

Warehouse Mgmt assigns a cost group to inbound
material at receipt.
Set up rules to determine the appropriate cost
group based on item, item category, and supplier.
If the system does not find a appropriate cost
group it will assign default cost group of the SI
where the material is put away.
Cost groups are assigned by system when the
following transactions are performed
Material is put away in a storage locator
Material is cross docked
Any material movement in an operation plan
which is in inventory.

Put Away Rules

Put Away Rules

Possible uses of Put away rules
Direct an operator to put away an item in the same
locator where other quantity of the item already
resides.
This minimizes item fragmentation.
Prohibit commingling of different items or different
lots of the same item in a single locator
Avoid lot commingling in a locator
Base the put away location on inspection results,
the type of purchase order, or item category
Direct operator to put away items based on
refrigeration restrictions
An operator can override suggestions of put away
rule, must provide reason code for override.

Restrictions and sort criteria for

Put Away Rules

Setting Up Put Away Rules

1.

Define Rules

2.

Define Strategies

3.

Assign Strategies

Setting up Put Away Rules: Define Rules

Setting up Put Away Rules: Define Strategy

Setting up Put Away Rules: Assign

Strategies to Business Objects

Put Away

Put Away Load

Put Away Drop

Put Away Drop

Put Away Drop Nested LPN

Item Based Put Away

Item Based Put Away

Cross Docking Put Away

Cross Docking to Outbound staging Flow

Advance Task Framework (ATF)

Advanced Task Framework
Model and Manage Complex Inbound Business
Processes

The Advanced Task Framework is:

Tailorable
User-definable
Balances Work load

Advance Task Framework

Advanced Framework enables to configure and
execute complex material flows for inbound items.
Plan and configure material flows to address specific
business objectives. It also simplifies the inbound
material movement execution process.
ATF enables to
Perform multi-step material movement
Define sequence of operations to be performed
during material flow
Define predictable material movement paths
Perform advanced operations such as
incremental consolidation, sorting, and packing
Use zones to balance workloads
Monitor progress

ATF Capabilities

ATF Capabilities

Use ATF to perform following functions:

Consolidation of similar items for palletization
Consolidation of items going to the same location
Deconsolidation of LPNs with mixed items
Movement of material requiring inspection to inspection
location
Movement of loose material to packing station
Use of Pick and Drop Locator to Perform an "n" step put
away

ATF Concepts
Activity: An activity can be defined as one or more
consecutive operations performed on material in a
warehouse in order to accomplish a specific
warehousing function. Example-Put away
Operation Plan: Planned sequence of operations.
Three types of operations are Standard, Inspection,
Cross dock
Load: Load is the act of picking material from a
locator and transferring it into the hands of an
operator, onto equipment, into a tote, or onto a
conveyor. An operator performs loads when material
needs to be moved. Loading is the first step performed
for material movement.
Drop: Drop is the act of dropping loaded material
into a locator. A load operation should always precede
a drop operation.

ATF Concepts
Task: A task is the unit of work a warehouse
performed by a warehouse worker, automated
equipment, or a work-equipment combination.
A task and a operation are two different things. A task
is the work performed on the warehouse floor, where
as operation is what defines the task to perform.
A task is an instance of an operation.
Material Grouping: use operation plans to control
material grouping in locators and LPNs during
intermediate moves. Consolidate material in a locator/
LPN based on Destination / Operation / Subinventory /
Similar item.

ATF Concepts

ATF Example

ATF Example
ATF applies to standard and inspection receipts. ATF
cannot be used for Direct routed receipts. Above
example is complex receiving process use ATF to map.
Material received into the R1.1.1 receiving SI is routed
to either to the inspection area, to inventory, or to an
outbound staging area.
Each operation shows how material moves through the
warehouse. The rules engine selects the operation plan,
the material is moved from operation to operation until
it is finally inspected, put away in inventory, or crossdocked

ATF Setup
1.Zones (Optional)
2.Put away rules (Optional)
3.Put away strategies (Optional)
4.Strategies Assignment (Optional)
5.Defien operation plans
6.Define operational plan rules

ATF-Zones: Setup

ATF Operation Plan Setup

Warehousing Features
Describe Warehouse Mgmt vs. partner
label printing responsibility
Define printers
Know what to print
Describe task types
Describe resources
Explain the Warehouse Control Board

Compliance Labeling

Warehouse Mgmt vs. partner label

printing responsibilities

Label Printing Components

Setup
Register label formats
- Associate label formats to label types
- Specify list of used fields
Assign label types to business flows
Build labeling rules
Define printers
Assign printers to label types

Registering label Formats

Assigning label types to business flows

Label format Assignment Rules

Defining and Assigning Printers

Printing Mode

Profile Options:
WMS: Print Mode determines print mode

Asynchronous Mode

Synchronous Mode

Synchronous Mode TCP/IP

Viewing Label Requests