Training on 11i.

10 enhancements
for Infosys

Oracle Process Manufacturing

5th January 2005

1
 Agenda

 Process Manufacturing
 OPM Positioning
 Introduction to OPM
 11.5.10 Enhancements
 Future Direction
 Questions and Answers
Process Manufacturing Market Profile

Chemicals, Paper, Metals,

Pharmaceuticals Fibers, Earth Products
46%
20%
Beverages,
Foods
34%

Industry Focus
– Pharmaceutical & Biotechnology Process 40%
– Food & Beverage
Discrete
– Chemical
– Metals & Paper
– Building Materials
 Variability Process -
Discrete - and it kind of works
it works
The Supply Chain
 Making “Stuff” vs. “Things”
Manufacturing Process
and Supply Chain Manufacturing
 Discrete Manufacturing  Process Manufacturing
• Uses Bills of Materials • Uses Formulas
• Builds, Assembles, Fabricates • Mixes, Blends, Transforms
• Makes “THINGS” • Makes “STUFF”
 The Physical Inventory Test

Count the computers, count the coffee

Cup, OZ, CC, ML, inches…

One % coffee (cream and sugar?)
% Coffee Solids

Discrete Assumptions vs. Process Realties

 Material Changes With Time

 Discrete Assumption
– Constant through time
Time

 Process Realities
– Varies through time

Time
 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
Discrete Simple Process Complex Process
Item Number Item Number Item Number
Location Location Location
Quantity Quantity Quantity
Unit of measure Unit of measure
Tank/silo Tank/silo
Lot number Lot number
Aging information Sub-lot number
Classification Container ID
Container type
Aging information
Catch weight
Classification
Quality
Hazards Information
 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
– 1+1 always = 2
 Always made the same way
 Bill of Material Assumptions
And Process Realities
many
 Many components make one end item
– The “A Bill” and the V, X and I bills
 Predictable in what is made NO!
– A + B always = AB A + B hopefully = AB
 Predictable in how much is made
Not
– 1+1 always = 2 1+1 approximately = 2
 Always made the same way
NO! Fresh vs. frozen ingredients, quality, line, seasonal
differences, etc.
 Variability in Process Manufacturing
Quality Attributes
Multiple Units of Measure

Yields

Complex
Costing

Status
Grade
Lot Sizes
Shelf Life

pH Factor Sequencing
Seasonality Catch Weight
 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!
 Unique Process Requirements

 Lot Traceability
 Packaging
 Regulations – FDA & MSDS
 Sub Lot Requirements
 Catch Weight
 Scheduling Needs
 Agenda

 Process Manufacturing
 OPM Positioning
 Introduction to OPM
 11.5.10 Enhancements
 Future Direction
 Questions and Answers
 Business Pressures
Variability Regulatory Compliance
• How do I create consistent • How do I comply with global
products using inconsistent and local requirements?
ingredients?
• How do I ensure lot traceability
• How do I achieve process and adhere to standards such
and reaction stability? as 21 CFR Part 11?

Raw Materials, Value-Added Finished

Ingredients Transformation Goods

Reduced Time to Market

• How can I manage a growing Lowest Total Cost
list of key product attributes? • How can I meet quality,
• How can I efficiently mass delivery, and service demands
customize my products? at a competitive price?
 Operational Challenges
• Limited joint development
with poor recipe reuse

SUPPLIERS R&D LAB CUSTOMERS

• Material push • High variability in release-to-

volume-production process
Materials, Finished
Ingredients, Goods,
Quality Docs
PROCESSING PLANT By- / Co-
Quality Docs
Products

Step 10

Materials Step 30 Step 40 Step 50 Finished

Inventory Goods

Step 20

Waste

• Documentation required at every step for traceability & compliance

• No status visibility between supply chain partners
• Inefficient material and capacity utilization
 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

 Oracle: Built for Process Industries
Customer Supply
Relationship Develop Chain
Management Sell Management
Plan
Finance
Market
HR Projects Source
Maintenance
Service
Process
Fulfill Manufacture

Data Applications
Server Server
OPM for the
Industries
OPM Customers
 Consumer Goods Capabilities
Evolution of Oracle Applications in Consumer Goods
Current Differentiators… …with 11i.9… …new in 11i.10
• Mixed Mode Manufacturing • Process Manufacturing • Product Information Hub with
• Inventory Postponement –
21 CFR Part 11 Compliance UCCNet Support (11i.10+)
Optimization –
HACCP Quality Test Points • Discrete Manufacturing
• Supplier Collab & VMI –
Automatic Lot Grading – 21 CFR Part 11 Compliance

• Collaborative Planning
• Supply Chain Exception Mgmt • Continuous Real-Time Demand
• 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
–
Manufacturing Scheduler
• High Volume Order Processing
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
• 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.
OPM Consumer Goods Customers
 Life Sciences Capabilities
Evolution of Oracle Applications in Pharma / Biotech
Current Differentiators…
• 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
…with 11i.9…
• 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
…new in 11i.10
• 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.
Oracle Life Sciences Customers
 Chemicals Capabilities
Evolution of Oracle Applications in Chemicals
Current Differentiators…
• 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
…with 11i.9…
• 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
…new in 11i.10
• 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

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

Suite Vendors: offer integrated suite

Niche Players: claim “best-of-breed”, but

require large integration efforts
 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

 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
Recent Process Press

"Oracle now leads in

overall process ERP
depth and flexibility."
- Meta Group (2004)
 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
How Process Mfg Solutions Stack Up...
Capability Oracle SAP SCT Ross/CDC

Recipe Rules-Based
Production
+ o - +

Multi-Level Lot
Traceability
+ o + +

Formula-Based MSDS
Development
+ + - -

Proactive Quality
Workflows
+ + o -

Multiple Simultaneous
Cost Methods
+ + - +

Activity-Based /
Lot Costing o o - o

Notes: + = Good, o = Neutral, - = Poor

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

Potency Allocations + o + +

Step-Level
Production Mgmt
+ + - +

Electronic Signatures + + - -

Complex Process
Modeling
+ o - +
Integrated
Catch-Weights
+ - + +

Notes: + = Good, o = Neutral, - = Poor

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
 Agenda

 Process Manufacturing
 OPM Positioning
 Introduction to OPM
 11.5.10 Enhancements
 Future Direction
 Questions and Answers
 Oracle Manufacturing
Product Family Mai
ntai
Process n
Design Plan Procure Fulfill
Mfg. and
Ser
vice
• Advanced • Advanced • Purchasing • Process • Order • Enterprise Asset
Product Supply Chain Inventory Management
• iProcurement Management
Catalog Planning
• Product • Configurator
• Sourcing • Complex
• CAD View • Inventory Development
• Advanced Maintenance, Repair
3D Optimization • iSupplier Portal
• Process Pricing & Overhaul
• Product • Global Order • Oracle Supplier Execution •
• Release CRL Financial
Intelligence Promising Network
• Process Management Management
• Demand • Procurement Planning
• Inventory • Network Logistics
Planning Intelligence
• Costing and Management (Network Asset
• Collaborative • Procurement MAC Tracking)
• Warehouse
Planning Contracts
• Process Quality Management
• Constraint Based • Services
• Regulatory • Transportation
Optimization Procurement
Mgmt
• OPM System
Admin
• ERES
 OPM Understands your
Business Flows...
Customers

Product Submit for

Specifications Ship Product Quality Analysis
by Grade Management

New Product Product Match

Required Customer
Exists Specs
Inventory
Trace Lots
Product Order
Development Management
Should Product Receive
be Produced? Supplier Lots

Optimized Schedule
Formula Batches Production
Approved

Product APS /
Suppliers
Costing MRP
Order
Requisition
Procurement
Raw Materials
 OPM Product Development
A secure, configurable environment for bringing new
products to market

Experimental Regulatory
Lab Batches
Recipes Documents

Research Plant
Develop Pilot Launch
Trials

What-if Workflow Based Production

Collaborate
Analysis Approvals Recipes
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
Quality Driven Product Attributes
Manage Variability / Sustain Product Consistency

Item 9FA123

Warehouse 200F (Aurora Whse)

Location Aisle 1, Row 1 Level 1 (1-1-1)

Lot Day Code; Batch #; Prod Run

Sublot Pallet; Case ID

Good/Hold/Reject
Precise Inventory Tracking Status
 Shelf life Grade/Spec A
 Retest interval
Multiple UOM LB/EA
 Potency
 User-defined classifications
 OPM Multiple Units of Measure

Standard:
1 Case = 10 LB 20.0 LB

vs

Lot 001- A Lot 001- B

1 Case = 10.5 LB 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
Multi-Level Material/Resource Traceability
Reduce Risk to Public Health and Brand Image

Lot Source

Ingredients Intermediate or Finished

Supplier Consumers
& Resources Bulk Products Product

Where Used

• Improve Recall Responsiveness / Cost

• Comply with FDA GxP and Safety Regulations
• Trace Materials Enterprise-Wide to Analyze Quality
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
 Oracle Process Manufacturing –
MRP
Demand The Planning Process

Forecast Customer order

Dependent Transfer out

demand

Supply
Material
Production schedule requirements
plan
Inventory Purchase order

Production Transfer in
 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
 Batch Processing Checks
Required e-signatures and QC test completion

Ingredient 1 Ingredient 2

10 Dispense
Resource+Activity Ingredient 4 Ingredient 5
Usage/Qty ERES

Start-to-Start 30 Blend QC step 40 Package

HOLD ERES
Resource+Activity Resource+Activity
Usage/Qty Usage/Qty

WF ERES
By-Product 1 Product 1
20 Weigh
Finish-to-Start
Resource+Activity
Usage/Qty ERES

Ingredient 3
Quality-Controlled Batch Processing
Control Production Variability with Quality
Checks

10 Weigh

Resource+Activity  E-Sign
Usage/Qty 30 Blend 40 Package

Resource+Activity  E-Sign Resource+Activity  E-Sign

20 Heat Usage/Qty Usage/Qty

Resource+Activity  E-Sign
Usage/Qty
Hold Step for Quality
Sampling and Testing

 E-Sign
 Oracle Process Execution
Solution
 Maximize production flexibility
Flexible scaling

 Increase plant efficiencies

ASCP, Gantt Chart, Automatic lot allocation

 Streamline reporting using backflushing and

API’s
Incremental backflushing, over 40 API’s

 Achieve product consistency

Simulator/Optimizor, Process Parameters, Processing
Instructions, Quality Testing, Electronic Records
Oracle Process Manufacturing Quality
Manage Variability and Assure Product Consistency

Inspection Points Integrations

• Receipt, WIP, shipping
• Lot expiration/retest
• Environmental monitoring
• 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 Results Compliance

• Tests & methods • Composite result statistics • Certificate of analysis
• Sampling plans (min/max, std dev, average) or conformance
• Specifications • Stability studies • Lot genealogy
• Input APIs • Output APIs • Electronic
recordkeeping
Process • Adjust batches
Improvement • Change formulation or procedures
 Workflow-Driven Quality
Management
Automate quality tasks and reduce lead times

Require Material Sample Creation

Inspection based Notification Workflow
on Specifications

Enter, Evaluate, Testing Notification Create

Composite Results Workflows Samples

Samples
Disposition Update Item
Workflow Lot Status/Grade
 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
 Oracle Process Manufacturing
Costing
Support All Phases of Costing

Material Acquisition Overhead Resource Indirect

Actual Standard Lot Composite

Cost
Monitoring Allocation Analysis Valuation
Development
Multiple Costing Methods
Supports different costing needs

Standard Costing Calculates based on

formula and routing
cost rollups
• Calculates based on
Actual Costing
actual production data
and allocations

Lot • Calculates based on

Costing actual production data
for a specific lot
 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
 Evolution of Oracle Process Manufacturing
Current Differentiators…
• 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
…with 11i.9…
• 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
… new in 11i.10
• 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
 Agenda

 Process Manufacturing
 OPM Positioning
 Introduction to OPM
 11.5.10 Enhancements
 Future Direction
 Questions and Answers
Topics
 Process Inventory
 Product Development
 Quality Management
 Regulatory Management
 OPM System Administration
 Process Planning
 Process Execution
 Process Costing
 Process Logistics
 Process
Inventory
New Feature Highlights
Process Inventory

 Lot UOM Conversion Update

 Automatic Lot Numbering Configuration
 Process to Discrete Inventory Transfer
 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
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
 Process-Discrete
Inventory Transfer
Process-Discrete Inventory Transfer

 New form to transfer inventory between

OPM organization and Discrete organization
 Controlled release
 Product
Development
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
 Recipe
Designer
Recipe Designer
– Designed for formulators and process engineers
– Enables creation and maintenance of Recipes
– User friendly interface
 Automatic
Recipe Generation
Recipe Generation

Upon creating a Formula, a Recipe and Validity

Rule(s) are generated based on user-defined rules

generates

Formula
Recipe + Validity
Rules
 Computer
Aided Formulation
Computer-Aided Formulation
Model Production Requirements to Target Specifications

Inventoried In-Process
Lot Properties QC Metrics

Computer-Aided Formulation
• Recalculate Material
and Yield Quantities
Target Product /
Product Recipe • Compute Batch
Characteristics (e.g., fat Customer Specs
content, potency, etc.)
• Automatically Revise
Lot Allocations

• Optimize Lot Usage / Production Batch Properties

• Use “What if” Simulation to Streamline Production Planning
Calculated based on
the ingredient
parameters
Formula or Batch Optimization
Optimization results
Optimization results
 Mass
Search and
Replace
Default
Status
 Quality
Management
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
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
 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

25°C
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)

Variant
A1
Glass
40°C
01 3 6 9

12 18 24 months
75% RH

Variant Plastic
40°C

A2 0123 6 months
75% RH
Initial Polyethylene 
Samples Variant 40°C
Batch A A3 75% RH 0 12 months
 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
Automatic
Sample
Creation
 Mass
Results
Entry
Regulatory Management
Regulatory Management

Document Creation to Document Management

iSign

MSDS
E-business Document
Suite System

Items Atrion & Wercs

Properties
Formula
Sales Info
Customer Info
Inventory Balance
Regulatory Features
 Document Storage and Retrieval (iSign)
– Document Security
– Approvals Management
– eRecords and eSignatures
MSDS
 Export APIs Supplier
Generation
– Items MSDS
Software Oracle Files
– Formulas Document
– Customers Storage
– Specifications
– Technical Parameters
– Item Properties
Customer
 Re-build Notifications MSDS
 Electronic Distribution
 OPM
Systems Administration
Archive and Purge

Test Run Archive Process Purge Process

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
Process
Planning
OPM Planning
• OPM MRP
• OPM- APS
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)
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
OPM Integrates with APS

– Integrated APS products with OPM:

 ASCP
 Demand Planning
 Manufacturing Scheduling
 Inventory Optimization
 Collaborative Planning
OPM
MRP
New Features for OPM PMRP

– Considers lot expiration

– Auto release suggestions
MRP Material Inquiry showing the
expired lot as a negative supply
(reducing on-hand to 25)
New Concurrent Program to
Release MRP suggestions
OPM with
ASCP
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
Detailed Feedback into Batches

– ASCP operation times & dates

update OPM batches

Planning Execution Shop Floor

Preferred Effectivity in Batch Creation

– Create the batch with the

Recipe/Validity rule selected in
ASCP
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
Firm Flag on Batch

– Firming a batch prevents

rescheduling by ASCP
Shift Simulation

– What-if capacity changes can be

modeled
Resource Exception Messages

– Over & under loaded resource

exceptions display in the ASCP
workbench
Bottleneck Resources

– ASCP will constrain only bottleneck resources

Auto Release of Suggestions
Full Auto Release

– Mass release – check “Production” box on plan

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

– Workbench release – check suggestions

– Profile: GMP:Auto Implement APS suggestions (YES)

Release
selected
suggestions
Auto Release of Suggestions
Semi-Auto Release

– Enter criteria to create batches

– Profile: GMP:Auto Implement APS
suggestions (OFF)

Enter
Parameters
In-line Forecast Consumption

– Forecast consumption now performed in the

APS engine enabling:
 Full use of Inventory Optimization
 Net Change capability with OPM.
Targeted Resource

– Update resource calendar availability

Line 2

Line 1
 Process
Execution
New Feature Highlights
Process Execution
 Resource Back Flushing
 Support for Shop Calendar setups
 Terminate Production Batch
 Resource
Backflushing
Definition: Backflushing

– Reducing the ingredient based on

standard formula/routing and the
finished goods completed
Resource Backflushing
Feature Overview

– Incremental Backflushing can now be

used to backflush resource usage in
addition to material usage
 Shop
Calendar
Support for Shop Calendar
Feature 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
Terminate
Batch
Terminate Batch
Feature 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
Process
Costing
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
 Lot
Level Costing
Process
Logistics
New Feature Highlights
Process Logistics
 Reservation Against Production Workflow
 Multi-Lot Receipt
 Control on Customer Returns
 Auto Allocation Enhancements (Shipment)
 Reserving
Against Production
Reserve Production for Sales Order
– Allows sales order reservations
against a Production Batch or Firm
Planned Order (FPO)
Reservation
converted to
Create Reservation Complete Batch
inventory allocation
Reserving Against Process
Execution Description

– Reserve against Pending and WIP Batches

– Reserve against Firm Planned Orders (FPO’s)
– Batch completion converts reservations into
allocations
– FPO reservations convert into batch
reservations
– Customer Service and Production monitor and
modify reservations
 Reserving Against Process Execution
Reservation Rules Setup

 (N) Production Supervisor > Sales Order

Reservations

Time period for

which to display
batches and FPO’s

Allocation Priority
for over-allocation
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
Reserving Against Process Execution
Reserve Production

 (N) Order Management > Orders > Sales Orders

This tab shows

batches and FPO’s
that can be reserved

User enters
reserved
quantities
Reserving Against Process Execution
Convert FPO to a Batch

• FPO Reservation is converted to a batch

reservation
• FPO’s can convert into one or more batches
Reserving Against Process Execution
Monitor Reservations

 (N) Production Supervisor > Sales Order

Reservations
Find
reservations
based on sales
order or batch

Modify reserved
quantity, if
needed
 Multiple
Lot Receiving
Receiving Multiple Lots
Description

– Quick entry of multiple lots in Receiving

– Uses automatic lot number generation
– Typing aid for users who receive many lots
against one Receiving line
Customer
Returns
Controlling Customer Returns
Description

– Validate lots and sublots for a return

– Control level of validation required
– Integrates with receipt recorded in Purchasing
Automatic
Allocation
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
 Agenda

 Process Manufacturing
 OPM Positioning
 Introduction to OPM
 11.5.10 Enhancements
 Future Direction
 Questions and Answers
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
QUESTIONS
ANSWERS