Creating Recipe in Oracle Process Manufacturing (OPM)

Recipes standardize the structure of all information that describes production of one or more products. Recipes contain the minimum set of information that uniquely defines the manufacturing requirements for a specific product.

To provide the greatest flexibility to process manufacturers, formulas and routings are built independently. They are linked using a recipe and its validity rules.

Pre-requisites:

Formula – Click the following, link to know about defining a formula

http://dj-oracleapps.blogspot.in/2014/02/creating-formula-in-oracle-process.html

Routing - Click the following, link to know about defining a routing

http://dj-oracleapps.blogspot.in/2014/02/creating-routing-in-oracle-process.html

Navigation: Process Engineer > Recipes

 

Enter the Code for the recipe, Version & Description of the recipe.

Enter the Formula to be associated with the recipe; the main product of the formula will appear in Product field.

The Quantity displayed is the sum of the product quantities entered in the formula. UOM is the unit of measure for the formula associated with this recipe.

Enter the Routing to be assigned with the recipe.

Enter the Owner Organization. In order for us to enter or edit information for the recipe, we must have an association with this organization and permission to access and change this field.

Process loss fields will be defaulted based on the routing assigned.  If needed except Theoretical Loss, Planned Loss & Fixed Loss values can be changed.

Note:

If a routing is not associated to a recipe or if a routing class is not associated to a given routing, and process loss is not defined for that routing, these fields will be blank.

Enter Recipe Type as,

• Master to indicate the recipe is process cell specific. Master recipes define exactly how a product is made in a specific process manufacturing cell.

• Site to indicate the recipe is site specific. A site recipe has the same structure as a general recipe, but can be modified for the local language and unit of measure. It can be modified to account for local material availability.

• General to indicate the recipe is a general recipe for the specific product variation made by the company. The general recipe is usually created during or after the pilot plant scaleup of a research and development recipe.

Select the Calculate Step Qty indicator to let the application calculate step quantities automatically. Quantities are based on the amount of materials that go into and out of each supported step.

Select Contiguous if routings in this recipe must be run in one contiguous block of time. The batch that uses this routing cannot stop and start, even if it runs into downtime on the shop calendar.

Total Output Qty displayed is the sum of products & byproducts mentioned in the Formula.

 

Plant/Laboratory:

Enter the Organization for which the process loss is being defined for.

Type indicates whether the organization is Plant or Laboratory.

Process Loss displays the material that is lost through the process. This field is blank if you did not enter a routing. If needed, you can override the default process loss values.

 

Customer:

Entering information’s in the tab is optional.

Enter the Customer number.

Name indicates the name of the customer associated with the customer number entered.

Operating Unit is the parent organization associated to the customer entered.

Ship to Locator is the customer’s postal address.

 

Step Quantity:

If a routing was not entered, then this region is not available. On entering the Routing code, the steps associated in the routing will be defaulted.

Step Quantity value is based on the calculation of Quantity, Step Qty entered in Routing and Total Output Qty entered in recipe.

For Example, in the routing associated Quantity entered is 200 KGM & Step Quantity is 50 KGM. In the recipe the Total Output Qty is 175 KGM.

Step Qty / Quantity > 50/200 = 0.25

175 * 0.25 = 43.75

Charges display the total calculated charges for the step. Charges are the number of times the operation must be performed to complete the step for the specified step quantity.

 

===X===

Creating Formula in Oracle Process Manufacturing (OPM)

Formulas in OPM are the same as bills of material (BOM) in discrete manufacturing. In this post we will see how to create a formula.

Navigation: Formulator > Formulas

 

Enter a formula name

Status – Whatever the default formula status provided for the organization in ‘Product development parameters’ appears here.

Navigation: Product Development Security Manager > Organization Parameters

 

Class - Enter a class for formula to identify how it is categorized. Classes are created in ‘Formula Class’ window,

Navigation: Formulator > Setup > Formula Class

 

Enter the Organization in which this formula should be used.

Enable ‘Scaling Allowed’ checkbox to indicate the formula allows scaling.

Enable ‘Packaging’ checkbox when the formula is a packaging formula.

Enable ‘Calculate Product Quantity’ to indicate the formula automatically calculates the quantity for products with the Proportional scale type.

 

Products:

Enter the Item code of the product which is produced in this formula & quantity of the product that this formula yields.

The product quantity defaults if ‘Calculate Product Quantity’ checkbox is selected.

 

Select the ‘Scale Type’ as,

Fixed - if the product is not scalable.

Proportional - if the product is scalable.

Select the ‘Yield Type’ to indicate the type of product yield as,

Automatic - when products are yielded automatically when the batch is completed.

Manual - when products are yielded manually.

Incremental - when product is yielded by incremental backflushing.

Automatic by Step - when products are yielded automatically as the step is completed.

‘Cost Allocation’ indicates how the cost of this item is allocated for financial roll-up purposes. 

Ingredients:

Enter the Ingredient & qty required to manufacture the Product

 

Select the ‘Scale Type’ as,

Fixed - if the ingredient is not scalable.

Proportional - if the ingredient is scalable.

Integer - if the ingredient is scalable by multiples.

Note:

‘Scale multiple’, ‘Scale rounding variance’ & ‘Rounding Direction’ fields will be enabled only when the Scale type is ‘Integer’

Enter the ‘Scale Multiple’ as the scaling increment for the ingredient.

Enter the optional ‘Scale Rounding Variance’

Enter the ‘Rounding Direction’ as,

Down - if the acceptable rounding direction is down to the nearest multiple.

Either - if the acceptable rounding direction is up or down to the nearest multiple.

Up - if the acceptable rounding direction is up to the nearest multiple.

 

Select the ‘Consumption type’ as the same way explained in ‘Yield type’ in ‘Products’ section.

Select ‘Contribute to Yield’ as Yes or No to indicate whether the material contributes to the yield

Select ‘Contribute to Step Qty’ as Yes or No to indicate whether the material contributes to the to the step quantity.

Select the ‘Phantom Type’ as,

Not a Phantom – if the ingredient is not a phantom item.

Automatic Generation - if the ingredient is a phantom item that is exploded automatically.

Manual Generation – if the ingredient is a phantom item that requires manual explosion.

 

‘Buffer’ specifies those ingredients that are used to maintain the target quantity while working with a formula or batch on the Simulator. The Calculate indicator on the Optimizer window is the default for all the ingredients selected as buffer in the formula.

Enter ‘Scrap Factor’ as the anticipated amount of ingredient lost in the manufacturing process as a percentage. For example, if the scrap factor is 7 percent, then an additional 7 percent of material is added to accommodate for this loss.

‘Required Qty’ displays the result of multiplying the formula quantity by the quantity one plus the scrap factor expressed as a percent.

 

By-products:

By-Products are not mandatory to create a formula, Enter By-products only when the process produces a byproduct.

Enter the By-product code & qty that this formula yields.

 

Select ‘Scale Type’ & ‘Yield Type’ as explained above in Products section.

Enter the ‘By-product Type’ as,

Rework - if the material generated requires rework.

Sample - if the material generated is used as a sample for quality inspection.

Waste - if the material is a waste product.

Yield - if the byproduct is material that is yielded for use in another process.

 

The created formula will be used in recipe.