Saturday, May 29, 2010

Oracle Work In Process

Oracle Work in Process is the core of Oracle’s Discrete Manufacturing Solution. Oracle Work in Process by itself provides a complete production management system that improves productivity, quality, and responsiveness while maximizing throughput and production. In conjunction with other modules within Oracle Discrete Manufacturing foot print, Oracle Work in Process provides support for enterprise wide quality management, lot and serial genealogy and traceability and support for various methods of planning and cost accounting, irrespective of whether your entire manufacturing is in-house or you use services of contract manufacturers.
Thanks & Regards,
S.Grace Paul Regan

Thursday, May 27, 2010

Discrete Jobs

Definite quantity of job used to manufacture the quantity.
II. Types of Jobs
i. Standard
ii. Non- Standard
Standard Job will have the assembly with the defined Bill, Routing structure from BOM.
Job Type of Standard identifies the job as being: A discrete job that controls the material and operation
requirements used to build assemblies and collect manufacturing costs
Nonstandard Job Type identifies the job as being:A discrete job that controls the material and collects costs for
miscellaneous activities, such as:
Rework
Field service repair
Upgrade
Disassemble
Maintenance
Engineering prototypes
Thanks & Regards,
S.Grace Paul Regan

Wednesday, May 26, 2010

WIP Accounting Classes

WIP Accounting classes are used to assign valuation and variance accounts for jobs. The data below Shows the wip accounting classes to be used for different type of jobs in SSL.
S.No -------- Discrete Job Type --------------------WIP Accounting Class
1 ------------Standard -------------------------------Standard
2 ------------Non Standard Asset --------------------Non Std A
3 ------------Non Standard Expense -----------------Non Std Ex

Thanks & Regards,
S.Grace Paul Regan.

Tuesday, May 25, 2010

Supply Type

i. Based on Bill
Components required for the Bill has to be issued. Method of issuing the components is given as supply type in Bill of Material. If we can use the same , select based on Bill.
ii. Push
If all the components to be used as PUSH type, select PUSH. In PUSH, we need to issue the components through WIP Component Issue transactions before starting the Job.
iii. Operation Pull
Components Issue will be taken care of by the system itself. Once the operation is completed, required components will be pulled from the mentioned supply subinventory .
iv. Assembly Pull
Once the assembly is completed, required components for that assembly will be pulled from the given supply subinventory.
v. Supplier
Issue of item by supplier, need not to transact this item . It is only for reference only to the WIP Person as this component need not to be used.
vi .Bulk
Bulk component requirements can be viewed and are displayed on reports. They can be used to communicate to the shop floor that bulk components must be used but need not be transacted.Bulk supply type components are not backflushed nor do they default when issuing all components for an assembly. we can, however, manually issue specific bulk components to a discrete job or repetitive schedule.

Thanks & Regards,
S.Grace Paul Regan.

Tuesday, August 25, 2009

Return back components after Operation Pull and Assembly Pull

Backflush transactions 'pull' components with Operation Pull and Assembly Pull supply types from inventory onto jobs and repetitive schedules. Backflush transactions can be launched by:
o completing assemblies at operations using the Move Transactions window
o moving and completing assemblies into inventory using the Move Transactions window
o completing assemblies into inventory using the Completion Transactions window
o receiving assemblies from an outside processing operation using the Oracle Purchasing, Enter Receipts window
Move transactions imported through the Open Move Transaction Interface can also create backflush transactions. Transactions imported through the Oracle Inventory, Inventory Transactions Interface can also create backflush transactions.
Additional Information: Backflushing reduces the number of manual material transactions required to process the discrete jobs and repetitive schedules.
Reverse Backflush Transactions
You can reverse backflush transactions and automatically return backflushed components back to inventory. For example, pull components that are backflushed as you move assemblies forward in a routing are automatically returned to inventory when you move assemblies backwards. Reverse backflush transactions can be created as you do the following:
o reverse operation completion transactions using the Move Transactions window
o return completed assemblies from inventory to jobs and schedules using the Completion Transactions
o move and return assemblies from inventory to jobs and schedules using the Move Transactions window
o return or correct transaction receipts in the Enter Returns or Enter Corrections windows in Oracle Purchasing.
Move transactions imported through the Oracle Work in Process Open Move Transaction Interface can also reverse backflush transactions as can return transactions imported through the Inventory Transaction Interface.

Note: You can, if necessary, issue and return pull components to and from jobs and schedules to inventory using the 'Specific Component' option in WIP Material Transactions window
Backflush Supply Subinventories and Locators
Sufficient inventory must exist in a component's source subinventory and locator for backflush transactions to complete successfully. If there is insufficient on-hand inventory to satisfy backflush demand, the supply subinventory balance is forced negative even if the Oracle Inventory Allow Negative Balance parameter is set to No.
The one exception is if the component you are backflushing is under lot, serial, or lot and serial number control. In this case you cannot complete the backflush transaction until you select a subinventory and locator that contains a sufficient quantity of valid lot and/or serial numbered items.
Supply subinventories and locator can be defined at the item or bill of material component level. If they are not defined, the system uses the supply subinventory and locator specified by the WIP Backflush Supply Subinventory and Locator Parameters when components are backflushed.
To ensure adequate supply for backflush transactions, you can replenish supply subinventories and locators as required.
Revision Control
For component items under revision control, the system always defaults the revision based on the item's current revision as of the date of the transaction.

Thanks & Regards,
S.Grace Paul Regan

Monday, November 17, 2008

WIP-Questions

1. Which intra operation steps might you want to enable if you have a just-in-time production environment?
Ans: You would probably enable only Run and To Move to model your environment.

2. You cannot move more assemblies than are available at a routing operation.
a) True b) False

3.What are the three transaction available in WIP?
Ans: Material transaction, Move transaction, Resource transaction.

4.When the lot based resource gets charged?
Ans: When the first unit is moved, the lot based resources will be charged.

5.In a assembly, all the components have supply type as operational pull, they are serial controled. During move transaction, how we can select the serial numbers.
Ans: During move transaction, a window “ Backflush” will popup, there we can select serial numbers.

6.For an assembly, the move transaction does not allow me to complete in that screen iteself? What will be the problem.
Ans: The assembly will be serial control, therefore you have to complete it in completion transaction screen only

7.In an assembly, one of the item has supply type = bulk, what transaction should i perform.
Ans: no need to perform any transaction, it is just a label.

8.In profile option, WIP: Define discrete job, it has been defined as concurrent. While creating a Discrete order, what concurrent will be running?
Ans: WIP concurrent exploder.

9.Explain shopfloor status?
Ans: Shop floor status are control move transactions which can be assigned to interaoperations steps.

10.What are the two types of scheduling available in WIP?
Ans: Dynamic lead time offsetting and Detailed scheduling.

11. Which status in discrete job cannot be reversed?
Ans: Complete – No charges

12.Which field in Discrete job is non- editable before saving?
Ans: UOM

13.How can we add material and Resource in a discrete job? What is the implicaiton of this action on bills and routing?
Ans: In Job / Schedule details we can add materials and resource for the particulat order. This will be effect for this order only. Engineering BOM and Manufacturing BOM has no effect.

14.What is repetative schedule?
Ans: Repetative schedule builts an assembly on a line at specifited production rate and for specified number of days.

15.How can you reverse manual resource charges?
Ans: You can manually charge the same resource to the job or schedule and enter a negative value in the Units Applied field.

16.In Repetative schedule, while associating line and assembly, what will happen if we enter hourly prodcution rate higher than the maximum hourly rate defined in production line?
Ans: An error message will pupulate and wont allow to enter quantity greater than maximum hourly rate defined in production.

17.What are the different rescheduling options available in WIP?
Ans: Forward , Backward and Midpoint.

18.For a purchased item, how “processing lead time” is calculated in WIP?
Ans: WIP won't calculate “Processing lead time” for purchased item, we have to manually enter.

19.In OSP, what will happen if we receive quantity greater than PO quantity?
Ans: we cannot close the job, it will be shown in pending transaction.

20. In an assembly, same component is used in operation 10 (first) & 50 (last). How to specify this in a bill?
Ans: Use reference designators to generate a range of Notion numbers with referencing to the specific operations. This might be drawing conventions, general informations..Etc

21.I want to check what are all the components used for final assembly, their qty, the routing & availability of child assemblies in Inventory. After checking, I want to convert that into discrete job. What is the facility given by oracle to do the above scenario?
Ans: Use “Simulate discrete Job”

22.I use Substitute items in WIP material transaction?
a) True b) False

23.What are the controls available to generate requisitions during OSP process?
Ans: In WIP Parameters, Operation start time of OSP operation (Queue Stage in OSP),At the time of creation of Job/schedule, Manual

24.Can we add an operation after it starting prodction. ( partial move transaction)
a) Yes b) No

25.Explain the status “ Pending Mass loaded” in Repetative schedule
Ans: The out put of MRP will be “ Pending Mass loaded” , since MRP does not consider existing schedules.

Descriptive Questions


1.What are the types of WIP accounting class available in Oracle?
Ans: Standard, Asset non-standard, Expense non-standard, Repetitive, Standard lot based, Expense non standard lot based, Maintenance.

2.Client is Pen manufacturer, He uses discrete manufacturing for his production. he sells pens and refills (as spare), During manufacturing of pen, refill is one of the component and it is non stocked . What setup to be done to manufacture and sell both pen and refill ( instead of defining two seperate items for refill)
Ans: Create items Pen and refill with supply type push / pull
Creat bill for pen, attach refill as its one of the component,
Change the default supply tpe to Phantom. ( this will effect this particular bill only)

3.What is the difference between “ Complete” and “ Close” ?
Ans:
S.No Complete Close
1 When completed, the WIP value gets decremented and Inventory value gets incremented When closed, the details are transferred to GL
2 Valuation accounts gets hit Variance account gets hit

4.In a Routing, an items’ manufacturing process is as per below..
10- Assembly
20 -Cleaning
30- Labeling
40- Inspection
50- Packing ,Here 40, Inspection is an occasional operation, not always be done. & 20. Cleaning is always done but non-critical. Hence these are requested not to be done while performing “ Move transaction “ in-order to have less manual effort. How to designate this requirement?
Ans:In standard operation, 20. Cleaning – Disable “ Count Point” & Select “ Auto charge”. This will not default this particular operation in the move transaction. This way can skip that particular operation.
40. Inspection, Count point & Auto charge to be disabled. Hence whenever occasional need calls, Add this operation to the Job by Job/Schedule Operations.

5.Create Discrete JOB for 10 nos, complete only 5 leave the remaining is Rejection. Hence this rejected qty not to be considered while booking sales order? What setup to be done so that can be avoided?
Ans: Create a Sub-Inventory and disable “Allow reservation – No”. (Call it as Rejection sub inventory)
Assign this DJ – Routing __ completion sub inv, so as rejected components can be moved here while Making “Move transaction”
Can check in the Availability window in the sales order screen, Available to reserve qty.

6.What are some reasons Oracle Work in Process would prevent you from performing a completion transaction?
Ans: There is no available quantity in the To Move step of the last operation in the routing.
–There is a shop floor status preventing movement from the To Move step of the last operation in the routing.
–The job/schedule status prevents transactions.
–The item is not transact able

7.what is the difference between Standard and Non-standard discrete jobs?
Ans:
S.No Standard DJ Non-Standard DJ
1 Standard DJ controls material and operation required to build assemblies and collect manufacturing cost Non-standard DJ controls miscellaneous activities eg: Rework, repair
2 Assembly in mandatory Assembly is not mandatory
3 We can “ Firm” Cannot check “ Firm”
4 Bill reference field is grey out Can enter item / assembly
5 Revision is not optional Revision is mandatory if the assembly has revision
6 Both Valuation and variance will be hit Only Variance will be hit

8.What are the status of DJ ( both user status and Processing status)
Ans
S.No User status Processing Status
1 Unreleased Pending routing load
2 released Failed routing load
Complete Pending bill load
Complete – No charge Failed bill load
Cancel Pending scheduling
Hold Pending closed
Closed Failed close


9.Can i complete an assembly with out order? Explain in detail

Ans: Yes, In Workorder less completion we can complete an assembly with out order.
Ther are 4 options available: WIP assembly compeltion , WIP assembly return, WIP assembly scrap, WIP return from scrap.

10.How to unclose an order, what are the prequestes for forecast

Ans: In Close Discrete jobs form query with the order number. Tools--> Unclose.
The prequestes are a) Job status should be closed.
b) Accounting period should be open

Thanks & Regards,
S.Grace Paul Regan