Defining Operations in Oracle Process Manufacturing (OPM)

Operations are a combination of activities performed in a production batch and the resources used to perform those activities. The Process Operation Details Activities window links operations to activities.

Navigation: Process Engineer > Process Operations

 

Enter the Operation code, version & description detailing about the operation.

Enter a Class for this operation to identify how it is categorized. Class is created in Process operation classes form.

Navigation: Process Engineer > Setup > Process operation classes

Enter the class code and description.

 

After entering the Process operation class, enter a Validate from & to date. By default the valid from date is system date. If there is no expiration date for this operation, leave the Valid to field blank.

Enter Owner organization for this operation.

Minimum Transfer Qty displays the minimum amount of material that must be produced in a step at a specific production operation and resource before the next operation can begin. It is used by planning to reduce bottlenecks by letting processes transfer an interim quantity of completed material to the next step without the requirement to complete the entire step.

Enter a Process Qty UOM for this operation

 

Activities:

To know how to define an Activity, click below link

http://dj-oracleapps.blogspot.in/2014/02/defining-activity-in-oracle-process.html

Enter an Activity required for this operation.

Enter the Activity Factor to specify the number of times the activity is performed in this operation.

 

Sequence Dependency is selected when the activity has a sequence dependent setup.

Enter the Offset Interval as the time delay from the start of the activity to the point where the resource is actually required.

Breakable indicates whether the activity can be broken.

Max Break indicates the maximum duration of the break if the activity is breakable.

Material Scheduled is used in conjunction with the planning and scheduling application to show the activity consumes material.

 

Now we have to assign the resource to activity (Resource used to perform the activity), Click Resources.

To know how to Create resource, click the following link

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

Enter the resource.

Throughput:

Enter the planned Process Quantity for the resource.

Enter the Planned resource usage

 

Cost Information:

The Component class field will be defaulted from Resource.

Cost Analysis code will be defaulted from Activity.

 

Scheduling Information:

Select the Plan type as per the need,

• Primary - Select Primary to indicate the rate determining resource. It limits or determines throughput. There can only be one primary resource.

• Secondary - Select Secondary for resources that work as companions with the primary resource.  Secondary resources affect the rate if the duration of the secondary resource is longer than the primary resource.

• Auxiliary - Select Auxiliary for resources that work as companions with the primary resources to perform an activity in the operation. Auxiliary resources affect the rate if the duration of the auxiliary resource is longer than the primary resource.

Enter the Count as the number of resources needed for the activity entered. For example, if two blenders are used for mixing, enter a 2 in the count

Enter the Offset Interval as the time delay from the start of the activity to the point where the resource is actually required.

Select the Scale type accordingly,

• Proportional - if the resources change in a ratio to the quantity of material being processed.

• Fixed - if the resources do not change, regardless of the quantity of material being processed.

• By Charge - if the resources change as a result of the number of charges specified.

 

===X===

APP-PAY-07900: This position is not valid for the duration of the assignment

While assigning a position to a newly created employee, the error message appears.

 

The issue is caused because the position is not valid for the entire duration of the employee (i.e) from the hire date of the employee.

In this case we created the employee on 14 FEB 2014 & created a new position with the start date of 17 FEB 2014.

 

Solution:

Create a position with a start date earlier than hire date of the employee.

We changed the position start date from 17-FEB-14 to 01-FEB-14. Assigned the position to the employee & saved.

 ===X===

Defining Routing classes in Oracle Process Manufacturing (OPM)

It is useful to set up process routing classes to group process routings with similar characteristics and requirements for reporting purposes.

Navigation: Process Engineer > Process Routing Classes

Enter the Class code, Routing class description & UOM for the class code.

 

For providing, Theoretical Process loss click Process Loss tab.

The Theoretical Process Loss window enables us to enter the hypothetical loss expected for a range of material processed during a specified routing. The loss could be attributed to equipment, evaporation, or any other aspect of the routing that detracts from the delivery of the full quantity of material added.

Enter the Fixed loss (if any) expected to happen during the specified routing.

For example, if you pack a quantity of material up to 100 KGM, then the predicted loss might be 2 KGM. However, if you pack a quantity between 100 and 200 KGM, then you might predict a loss of up to 3 KGM and so on. Record the process loss accordingly.

 

This routing class will be used while creating Process routing.

===X===

Creating Routing in Oracle Process Manufacturing (OPM)

Routings are sequenced sets of operations to perform in order to complete a production batch.

Navigation: Process Engineer > Process Routings

 

Enter the Routing code, Version & Routing Description that briefly describes the routing.

Enter a Class for the routing to identify how it is categorized. Entering process routing classes is optional.

To know, how to define routing classes click the below link.

http://dj-oracleapps.blogspot.in/2014/02/defining-routing-classes-in-oracle.html

Based on the loss specified in the routing class - Planned Loss, Theoretical Loss & Fixed Loss fields will get populated.

Enter the Process Quantity for this routing. Based on the quantity entered, Theoretical Loss might change (as per the loss provided in routing class)

Select Enforce Step Dependency to indicate the recipe using this routing enforces step dependencies. When you select this indicator, routing steps must be released and completed manually.

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

Enter the Owner Organization to indicate the plant, laboratory, or other facility responsible for initiating this routing.

 

Routing Steps:

Enter the Step number to associate with an operation in this routing. It is recommended that the first number in this sequence be 10, the second 20, and so forth. You can add intermediate steps between 10 and 20 at a later time.

Enter the code of the Operation performed in this routing.

Enter the operation Step Quantity as the quantity of material associated with this step.

 

Min Transfer Qty mentioned in the operation will be defaulted.

Select Release Type as,

• Automatic if the step is automatically released or completed when subsequent steps are released or completed.

• Manual if the step must be released and completed manually.

Note: All steps are completed if the batch is completed, regardless of the step release type

 

Step Dependencies:

The Routing Step Dependencies window lets us to create and modify routing step interrelationships. Step dependencies are those relationships between routing steps that establish whether a specific step can or cannot start until another step is completed.

For example, if step 10 is BAKING and step 20 is the COOLING step, and then step 10 must be completed before step 20 can begin. By this definition, step 20 is dependent on the completion of step 10.

 

Enter the Previous Step that the currently selected step is dependent on.

Select Dependency Type as,

• Start-to-start if the dependent step starts at the same time as the step on which it is dependent.

• Finish-to-start if the dependent step starts after the previous step ends.

Enter Standard Delay as the standard number of hours from the end of the preceding step to the start of the current step. You can also enter standard delay as the start of the preceding step to the start of the current step, depending on the dependency type entered.

If you enter a value equal to zero, then the step following the current step begins immediately after the step ends or starts. You can enter a negative standard delay if the dependency type is finish-to-start in order to create overlapping steps.

Enter Transfer Percent as the percentage of material that goes to the dependent step after all products and byproducts are yielded.

For example, If 40 percent of the material from the previous step comes into the current batch step as a result of 60 percent of the material going to another step, then enter transfer percent as 40.

 

The routing created will be used while defining Recipe.

===X===

Creating Resources in Oracle Process Manufacturing (OPM)

Resources are the assets you use to produce batches, including production equipment and employee labor. For each resource, you must assign a component classification code for costing purposes. You can optionally group resources into resource classifications. For example, Ovens and Stoves may be grouped into Cooking Units.

Pre-requisites:

Cost component class. Click the following link to know how to define cost component class

http://dj-oracleapps.blogspot.in/2014/02/defining-cost-component-class-in-oracle.html

Ensure that the unit of measure of time is established on the Unit of Measure window in the Oracle Inventory application.

Navigation: Process Engineer > Setup > Generic Resources

 

Enter a Resource code to identify the resource & Description detailing the same.

Enter Usage UOM by which you measure the amount of time used for processing this resource.

Enter the optional Resource class to which this resource belongs.

Enter Cost component class which links this individual resource to a unit of measure and allows you to establish costing parameters for the resource in the Cost Management application.

Capacity:

Enter the Minimum and Maximum per vessel capacity for this resource.

Enter the Capacity UOM for this resource.

Enable the Calculate Charges box if the capacity of an operation is constrained by the resource for the purpose of calculating charges.

If another capacity-constrained resource in the same operation has a smaller capacity, then the system uses the smallest capacity-constrained resource to calculate how many times an operation is repeated for the purposes of calculating charges.

Enter Capacity Tolerance; if the capacity falls within the specified percentage, then the resource is processed without calculating charges. If the material is over the capacity, then it is planned and scheduled incorporating calculated charges.

Enter the Utilization & Efficiency percentages; these are used by Planning and scheduling only.

 

-----x-----

Defining Activity in Oracle Process Manufacturing (OPM)

Pre-requisites:

Cost Analysis code – We have to assign an Analysis code to the activity. Hence first we will see how to create Cost analysis code.

Analysis Code:

An individual component cost identified by a particular cost component class can be further broken down using cost analysis codes for more granular tracking of costs.

Navigation: OPM financial > Setup > Analysis codes

Enter a code to identify the cost analysis type & description for the code

 

Use this cost analysis code while defining Activities.

Activities:

Activities are actions performed during production. Cost analysis codes are assigned to activities so that proper cost calculations are computed.

Navigation: Process Engineer > Setup > Activities

Enter the activity code, description and suitable cost analysis code.

 

=====X=====