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Integrated Supply Chain DemonstrationDiscrete & Flow Manufacturing OverviewLarry Mobley, P.E.AGSS – Solution Architect, Manufacturing Specialist

Training Agenda

• Overview of demonstration flow

• Key Take-Aways

• Demo Setup

• How to present / position

• Post Demo cleanup

Demonstration Description

• Demand for an AS88311 Vision Pad Mobile Computer is created for organization W1

• ASCP determines that the AS88311 should be sourced from organization M1, which uses Discrete (work order-based) Manufacturing

• ASCP also determines that a component of the AS88311 is the SB88328 PC Board Assembly, and it should be manufactured in organization S1, which uses Flow (schedule-based) Manufacturing

Demonstration Overview

DemandW1: AS88311 Vision Pad Mobile Computer

TransferASCPPlanned Orders

M1: AS88311 (Discrete)

S1: SB88328 (Flow) PC Board Assembly

Key Take-Aways

Flow & Discrete (Multi-Mode) Manufacturing can co-exist in one instance (they can co-exist in one organization, but that is not shown in this script).

Oracle supports an information-driven, manufacturing environment, including planning and execution (some of our competitors can only PLAN for these environments).

Integration to Quality requirements, established at project conception.

Oracle maximizes information availability on the shop floor, but minimizes intrusions for data collection.

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Demo Setup

Where to start……

At this point in the Integrated Supply Chain Demo, ASCP has been run and recommended some outsourcing and some internal manufacturing of the AS88311 (Vision Pad X100 - Mobile Computer) in M1. At a live customer, ASCP could also be used to automatically create manufacturing work orders in a “Released” status. Those work orders could immediately be executed on the shop floor. In addition, ASCP would plan the manufacture of any needed components, including the SB88328 (PCB Assy - Vision Pad DX) in S1. However, in this demonstration those orders are not created automatically, so you will need to create them as part of your set up.

Set ParametersLog on: mfg / welcome(N) WIP > Setup > ParametersOrg = M1

(T) Serial

Uncheck both boxes; then save

Create a Sales Order1) Customer Number = 1608 Order Item = SB88328 Qty = 400 (> 350) Sched Ship Date = (tomorrow or sometime next week) Whse = S12) (B) Book Order3) (I) Save

Create a Work Order

1) Org = M12) (N) WIP > Discrete > Discrete Jobs (B) New Assembly = AS88311 Status = Released Quantity, Start = (some quantity > 350) Dates, Start = (today)3) (I) Save; Exit

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And now, the demo….

How to Present / Position

• Present from the perspective of a Manufacturing Manager who has access to both organizations S1 and M1.

• Depending on your audience’s level of interest, this script can be accomplished with a minimum of steps. If there is interest in details, the script contains supplemental details that can be explored.

• At the end, restate the Key Take-Aways.

The whole flow

To this point, we have seen Oracle’s impact on the development and planning of the computer product. Now we will see how Manufacturing has been improved.

Opening RemarksOracle’s MES tools can be a great benefit to manufacturers in a wide variety of environments. Different companies will have different complaints. The following problems come from our case study, Turnaround, Inc., and are typical of some you may encounter elsewhere. (The following are issues and points that you, as a demonstrator, need to have fresh in your mind so that you can draw on these as they best fit the moment during your discussions.)

 

Turnaround, Inc., used to say:It takes too long to get a sales order into production – frequently have to wait overnight for planning and scheduling batch runs to create the work orders and to check component availability.There is too much WIP on the floor.It is hard to locate an order because there are so many, and heaven only knows at which workstation a particular order is located.If operator instructions exist at all, they are usually out of date and in notebooks that no one seems to be able to locate when they need them.Quality data collection is haphazard and dependent on the operators’ memory

Oracle Value Propositions

Flow Schedules can be created quickly, in one large collection, or the Scheduler can pick & choose orders to be scheduled: the Scheduler is in control of what gets put into the schedule.

Data collection systems are non-intrusive, or minimally intrusive, to productive work on the shop floor. Users/managers can make the workstation as simple or as comprehensive as they desire through configuration parameters. The point is that we try not to interrupt real work with a bunch of data collection.

The Operator can see their work at an operation level, or at a job level: an operator may post only their own work progress, or they may report for an entire line, in a single transaction.

Flow Manufacturing reduces WIP on the floor by virtue of the production “pull” philosophy: material is not moved forward until the next operation pulls it. And you can be comfortable with these lower inventory levels because of the “velocity of material,” which means that you are always building a little of everything, all the time. If you don’t have what you need right now, there will be more coming in a short while.

Oracle supports kanban replenishment to minimize issues with component availability. Again, using the “velocity of material,” components are always in motion in the replenishment loop. If they aren’t here right now, they will be arriving soon.

Turnaround’s Decision

Turnaround has decided that Flow Manufacturing is our future direction, but not all facilities are ready to convert from “push” manufacturing to “pull” manufacturing yet. A great advantage from Oracle is that we can run both in the same instance, even in the same organization. So, we have chosen to implement Discrete, work-order-based manufacturing in some facilities and Flow, schedule-based manufacturing in others. I’m going to show you an example of each. We will start with building the computer’s PC board in facility S1, using Flow.

Manufacturing Demand & Planning details

This is where our story begins.From the prior scripts, Sales has developed a demand for Vision Pad X100 - Mobile Computer, to be shipped from organization W1.

Operations Planning determined that the proper source for this computer would be to manufacture it in organization M1. And that it will require a component, PCB Assy - Vision Pad DX, from organization S1.

Manufacturing details

Our demonstration sequence, then, will be to create a Flow Manufacturing schedule in S1, and produce the PC-board component. This shows how the planner maintains control in a Lean environment. The component is then transferred to M1. Since the planning engine is able to create “Released” shop orders, we do not have to perform a scheduling function in M1 (demonstrating rapid response in discrete manufacturing); just build the final computer product. It is then transferred to W1 for customer distribution.

To execute the demo, simply click on the three boxes at the bottom, sequentially, from right to left.

Sizzle Log-ins

Demand forW1: AS88311

Transfer

ManufactureM1: AS88311Using Discrete

Generates sourcingrequirement forM1: AS88311

ManufactureS1: SB88328Using Flow

Generates componentrequirement forS1: SB88328

Transfer

Schedule Flow Manufacturing

ID: mfgPassword: welcomeOrg: S1Nav: Flow Manufacturing

> Line Scheduling > Scheduling Workbench

ID: OPR1Password: welcomeOrg: M1Nav: MES Workstation

Startup

ID: mfgPassword: welcomeOrg: S1Nav: Flow

Manufacturing > Home

Flow Line is PCB-ASM

We will be scheduling the Surface Mount flow line. We need to find all the planned orders that are not yet scheduled.

Flow Schedule Parameters

Order Type = Planned OrdersOrder Dates = today – end of next week,(B) Unscheduled Orders

Dates on the scheduler will default to today. We want to gather orders due between now and the end of next week and manufacture them today. So we must set the Unscheduled Orders date range and then click on (B) Unscheduled Orders.Note: in the upper right corner is the unit capacity for this line. If you try to schedule more than this, the system will automatically move the excess to successive days, depending on the scheduling rule you pick.

Filter for Scheduling1) Field= Item Condition= Equals From= SB883282) (B) Find

This will collect all open, unscheduled orders that meet your selection criteria. (If you leave the filters blank, the query will return unscheduled orders for all parts.)

Scheduling Orders

1) Select order

2) (B) Schedule

Here we see all the unscheduled demands. The Planner not only gets to choose which orders to include in the schedule, but also to override the Quantity to be produced in this new schedule.

Resulting Summary Schedule

(I) Save

Optional: click on (B) Details

Optional Talking Points

Unscheduled Orders: can add more orders to schedule

Component Availability: If ATP is set up, this will show details of components

When you finish your discussion here, go back to the Sizzle Flow diagram

Next is the Flow Workstation

Now, put on your safety glasses and we will go out on the production floor in S1 and build to this schedule.

Open Flow MES Workstation

Organization = S1(T) Workstation

- There are many features to show and you should feel free to show any one or all of them in any order you choose.

- There are two different views of the flow workstation that have been created. We will be showing most of the features in one view, and when you complete the line operation you will be able to see the different view. The difference is between tabs and all of the data displayed on the entire page.

Select workstation queue1) Organization= S1 Production Line= PCB-ASM Line Operation= BDZ1 From Completion Date= Today2) (B) Start

Additional filters for the workstation’s queue

Schedule Queue

- These are schedules, not work orders

- What the operator can see and do is completely configurable

- Describe displayed columns- Click to select one of the

schedule numbers- The bottom of the page

shows the operations, or Events. Click on Event Seq 100

Event Sequence details

- The top of this window shows identifies the operation

- The middle of the window shows work instructions (pictures, drawings, video clips, etc.)

Event Sequence details (cont.)

-(Optional) The bottom of the window shows the components, where the operator can trigger a kanban replenishment, or Update Components to enter any non-standard issue quantities (this is a whole different script to run kanban)

- (Don’t click) The ECO tab is of pending changes (implemented changes are already included in the routing or BOM)

- (Optional) You can also click on the Resource tab to see what is assigned

Schedule Completions

Show list of values at Complete Schedule

The operator has several choices for updating production progress, depending on whether each operator is responsible for only their own operation, or, to minimize data entry one operator reports for multiple operations. 1) “Complete Schedule” will execute the backflush of material and labor at this one step and move the item to the next operation; 2) “Express Complete Line Operation” will backflush all material and labor and will move the item to Finished Goods.Since this is a short and simple process (and reduced “clicks” in the demo), we will use the Express Completion.

Error because you skipped the test

Click on the icon to “Add Child Data”

Notice of mandatory test

Enter Test Data

- In the “Volts” column, enter a number, like 6 or 0.6

- In the Results” column enter “Passed”

- Click on (B) Apply

Now you can complete the schedule

Now the mandatory test is satisfied.Go back to the Sizzle Flow chart

Discrete MES is last

At this point, the SB88328s have been completed in S1 and transferred to M1 for consumption in the manufacture of the AS88311s. So now we proceed to the shop floor for M1 as an operator there.

Log into Discrete MES

It is possible to assign a workstation to a single resource, or person, or to share it. In this case, we will set it up to be shared by leaving the Resource field blank.

Organization= M1Department= Surf MountResource= (leave blank)(B) Start

Talking points: MES work queue

- In this screen we see all the work orders released and scheduled for this operation. We are interested in the job for the AS88311 computer (If it does not show, you may need to increase the “To Date” by a day).

- The green check mark in the third column indicates that all material and resources are available to begin production of this order.

- If you want, you can also click “Job On” to reserve the job to yourself (this can also be done by the supervisor to assign work to specific employees).

Update progress with Express Move

If this work order had multiple operations at several workstations, I could advance the work order from my station to the next one on the routing by clicking the Move Assembly Button. All material and labor defined for my operation will be backflushed automatically. If, however, this is the only operation, or the routing is short and I am responsible for reporting work on all steps on this routing, I can use the Express Move to complete all operations for the quantity I enter – all backflush transactions at all operations are automatically created and the order is completed to its finished goods inventory. To do this, I simply need to fill in the Quantity Complete and the Quantity Scrap, then click the (B) Express Move

Complete= 1Scrap= 0(B) Express Move

Work Order is gone from the queue(or W.O. quantity is reduced)

- Our work order is gone from the queue, or else it is reduced by the quantities completed, plus scrap, and the shop floor operator proceeds with the next work order.

- Segway: So we will leave Susan Banks there and go transfer our completed item to the warehouse, W1, for shipping to the customer.

- Return to the Sizzle Flow diagram

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Post Demo

Delete unused Schedules

Login ID = mfg Password = welcomeOrg = S1 Navigate toFlow Manufacturing > Line Scheduling > Scheduling Workbench

If you don’t use all of the planned Schedules in the Flow MES, you can “recycle” the uncompleted ones by deleting the remainders. Then those units will be available for the next run of this demo.

Return to the PCB-ASY flow line schedule

Line Code = PCB-ASM (B) OK

Locate your schedule

Schedule Dates (start) = (your schedule date) (B) Flow Schedule Summary

This should be your schedule

Use “Tools” to delete

(M) Tools > Delete Flow Schedules

Enter background process parameters

Start Date = (your schedule date)Line = PCB-ASM (B) OK

(B) Submit

View Revised Schedule

Use (CTL+F11) to update this screen. When the background job has finished, the schedule summary will only show the units you have completed. Save this revised schedule. Exit

Key Take-Aways

Flow & Discrete (Multi-Mode) Manufacturing can co-exist in one instance.

Oracle supports an information-driven, manufacturing environment, including planning and execution.

Integration to Quality requirements, established at project conception.

Oracle maximizes information availability on the shop floor, but minimizes intrusions for data collection.

Sizzle Diagram

Demand forW1: AS88311

Transfer

ManufactureM1: AS88311Using Discrete

Generates sourcingrequirement forM1: AS88311

ManufactureS1: SB88328Using Flow

Generates componentrequirement forS1: SB88328

Transfer

Schedule Flow Manufacturing