Oracle Process Manufacturing - Implementation Questionnaire

Inventory
--How many different products within the product line?
--Total how many ingredients and byproduct items present within the product line?
--Are there any intermediate items which are stocked in inventory?
--What are the main inventory keeping locations within the manufacturing plant
--Are Finished Goods Lot and Grade controlled?
--Are Raw Materials Lot and Grade controlled?
--What are the main unit of measures used?
--Is the stock tracking done in multiple units for the same item?
--Are different pack-sized Finish Products treated as different Items / SKUs?
--Is the shelf life maintained for different ingredients / products ?
--FG Storage happens in same warehouse or different?
--Reusable waste Storage locations?
--Are the Co-products produced during batch processing?
--Whether Items have Version control?
--Lot numbering/sequencing?
--How are packaging materials defined in inventory - Diff. item codes for diff type of containers / packaging?
--On what basis the material is moved from main storage to production floor?

Product Development
--Do multiple formulas / recipes exist for one product?
--Version control for formulas, recipes and routings?
--Codification logic for formulas, recipes ?
--How frequently does the formula / recipe change ?
--Process loss information available in formulas?
--Are scrap / waste items defined and used in formulas?
--Creation and Approval process of Recipe/Formula?
--How packaging waste is handled?
--Is there any tracking of technical parameters / process parameters like moisture content etc.in formulas / recipes?
--Are formula / recipes maintained in baan system ? Availability of data?
--Is the resource (equipment/man-power etc.) tracked in the system ; data availability?
--Are routings (operation steps) maintained in the system; availability of data?
--Are the packing materials defined as a part of formula?


Process Execution
--What % of production is MTO?
--What is the basis for daily production - Manual / System generated production schedule ?
--How many batches are processed within a day?
--Finished Good is produced through a single batch or a series of batches for different intermediates?
--What arte the intermediates which are stocked in inventory?
--Is there any sub-contracting process involved?
--How is production data captured presently? -- Through system driven batch execution or manually in excel sheets?
--How frequently production data is captured?
--What all information is captured for production?
--What is the general range of batch size?
--How is scrap generation and rejection process handled?
--How is rework process handled?
--How many shifts of production? Is there 24 Hr operation?
--Are the production batches linked to sales orders in "Make To Order" scenario
--Automatic numbering of batches?
--How is process loss tracked?
--Any inventory keeping locations within the production line or continuous process?
--How is variance tracking (between planned and actual usage - material / resources) done for production batches?
--What are the interaction points of production department with other departments?
--What all PLC / equipments linked to prouction system?
--What is the WIP reconciliation process followed at period ends?

Quality Control

--What are the different stages of quality inspection?
--How is the quality inspection data recorded - Manual or system ?
--Is the material tagged with quality grades after quality inspection?
--How is rejected item treated, what is the process followed for the same?
--Item / Vendor / Customer quality specifications maintained in the system ?
--Is quality inspection done on the basis of sampling plans?
--Criteria for defining inspection samples and conducting quality checks?
--Material expiry and shelf life tracking ?
--Quality department structure?
--How is communication managed between quality and other departments?
--Any approval methodology followed within QC ?

Costing
--Costing method for raw materials?
--Costing method for Finished goods?
--How is resource cost (equipment, man-power) tracked? Is it a part of FG direct cost?
--How is overhead cost managed ? Tracked at an aggregate level or product level?
--Present accounting process for production related transactions?