Mfg WIP Advisor Webcast 2013 1204

7/26/2019 Mfg WIP Advisor Webcast 2013 1204

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The following is intended to outline our general producdirection. It is intended for information purposes only, a

may not be incorporated into any contract. It is not a

commitment to deliver any material, code, or functiona

and should not be relied upon in making purchasing de

The development, release, and timing of any features

functionality described for Oracles products remains a

sole discretion of Oracle.

Safe Harbor Statement


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Oracle Advisor Webcast

Flow Manufacturing: An End to End Flow

Zar Ahmed


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Objectives

To understand the basicconcepts of FlowManufacturing (FLM)

Explain the required setups

To provide details of thebasic process flow of FLM


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Agenda

Overview

Basic Setup Steps

Process Flow using screenshot demo

Basic Technical Details APIs, Tables.

Q&A


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Overview

FLM (also called LEAN Manufacturing) is a manuapproach that aligns production with customer de

employs Just-In-Time (JIT) concepts such as : Manufacturing to demand (vs. forecast),

Production lines for families of products (vs. playout),

Pull material using kanbans (vs. push materia

Backflush material and costs upon completionoperation), and so on.


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Overview

Key principles of FLM are : Decrease Inventory. Eliminate waste the more stocking points you create, increases waste.

Continuous Production Line concept : so if you need to store your productcome off the production line, it is not really FLM. No idle resources.

FLM products repetitive tasks, same product produced (in discrete mfg, more tailored to specific customer needs).

Optimize machine utilization Reduce response time to customer needs Simplify shop floor activities. Production without use of work orders. Only one final product typically produced on the line. Raw Materials and sub-assemblies are added at different operations. Lower skill levels typically then in discrete manufacturing. Long production lines mean lower costs.


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Mixed-Mode ExecutionComplete Manufacturing Operations Management

Flow

Manufacturing

Shop

Manag

Best for

Flexible andConfigurable

Manufacturing

Execution

Capabilities

Make to order demand flowtechnology or lean mfg linesor cells in a low-to-mediumproduction volume, highproduct mix environment

Lot / serial conitems that requduring entire pLow volume devolume interfac

Oracle MES / MOC plus

Configurable work lists Paperless work instructions via graphically rich Streamlined transactions Supervisor dashboard to monitor shop floor stat Integrated quality data collection Product genealogy tracking Label printing (product identifiers, packaging, etc

Traditional manufacturersin a low-to-mediumproduction volume, highproduct mix environment

Production

Assembly

Mobile Supply Chain Applications

Discrete and Process Mfg


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Oracle Flow Manufacturing Solution

Holistic planning with consensus forecachannel order capture with global ATP

Accurately Plan andCapture Demand

Intuitive UI for paperless work instructioquality management and reporting

Execute in Real-Timewith Built-In

Quality Management

Support for mixed model production, grfor flow line design and balancing

Design for BalancedOperations

Schedule andSequence for

Efficient Production

User-definable scheduling and sequencwith integrated feeder line and supplier

Plan & ExecuteKanban Material

Movement

Complete Kanban management with pusequencing, Kanban planning and exec


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Flow Manufacturing Definition

Benefits:

Lean processes that are sustainable and repeatable on a global s

Speeds the introduction of new products to the Flow Mfg process

Supports continuous improvement in manufacturing processes

Integrated software that directly supports lean mfg / lean supply c

Lack of formalized, sustainablelean processes Lack of Lean Mfg integration

with core ERP data(e.g., cost accounting andorder management)

Demand-driven manufacturers in any industry

What Does it Do

Who is i t For?

Framework to document flow mfg

Simulates and calculates flow line Designs material replenishment p Sequences demand directly to pro Simulates daily demand for resou Provides line performance metrics

What Problems Does it Solve?


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REQUIRED SETUPS


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Summary of Setups

1. Define your items.2. Define your flow lines. These are manufacturing work areas where you p

assembly. Can manufacture multiple items on a flow line simultaneously.

your resources and departments.3. Product Synchronization : Define the products Process Flow using Flow

the processes and activities (events) and the line operations). Use GrapWorkbench for this.

4. Balance Flow Lines (balance resources and events) : Mixed Model Workused to do this. Calculates process times and required resources to do th

5. Create Pull Sequences for every item : FLM uses Kanban replenishmentmaterial requirements and pull material from demand sources.Pull Sequence = definition of the item, where it is used and where it is su

6. Setup Kanban Planning. Graphical Kanban Workbench : Kanban setup , define pull sequences, planning simulation , kanban transactions.


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Summary of Setups

7. Define Scheduling rules : Purpose of line scheduling is to synchronise prcustomer demand. Use Line Scheduling Workbench to achieve this.Define the scheduling rules that will be used for this.

8. Setup Sequencing Constraints : Sequencing is used to consider your demdetermine a sequence for building assembly items

9. Setup Flow Execution Workstation : This is used to meet daily production(flow line transactions, track work flow, complete assemblies, view comporesource information.

10. Enable profile FLM : Enable Flow Sequencing.


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Setup 1:Define Your Items


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Setup 1:Optional : Product Famil ies


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Setup 2 : Define Flow Lines

.Mfg Work Area where the assembly is produced.


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Setup 3 : Product Synchronization

Define a Flow Routing


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Add Events, processes and Line operations


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Events : Detailed Work Content of the Line


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Processes : Optional. Discrete Grouping of the EventsUsed to look at balance of the shop using MMW before mov


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Operations : Grouping events into your line workstations.


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Setup 4 : Balance Flow Lines (MMW) Line Balancing : Process of defining balanced production lines by including productsperformed and materials and resources consumed at each step. The idea of line balancing is simply to meet the required demand in the quickest tim MMW : Used to balance lines against specific demand and calculate process volum

requirements, TAKT times and in-process-kanban (IPK) requirements. TAKT = rate at which products must be produced to meet schedules.

S 4 B l Fl Li (MMW)


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Setup 4 : Balance Flow Lines (MMW)Amend assignments; simulate ; balance.Actions used to balance lines include : reduce or remove non-value added work, grousmaller or larger units, increasing resource, increasing in-process inventory, adding add

Line Design and Balancing


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Line Design and BalancingSimplify Production Modeling

Li

MixeW

Define processesDefine and associate processes with productfamilies, items, or configurable models

Model pr imary & alternateproduction paths

Link operations together as primary, feeder and /or rework processes

Assign workcontent times

For each process, create a detailed sequence ofevents, or estimate time

Share processes & eventsbetween assemblies

Define standard processes and standard events,or common product family synchronizations

Perform mixedmodel calculations

Calculate line and operation takt, and reqdresources; highlight imbalances

Balance lineDefine balanced operations, add IPKs,add resources

S t 5 KANBAN SETUP


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Setup 5 : KANBAN SETUP

S t 5 D fi P ll S


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Setup 5 : Define Pull Sequences

Pull Replenishment : To signal Material requirements.

S t 6 K b S t D fi d L


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Setup 6 :Kanban Setup Define and Lau

Define your planLaunch Plan creates the Kanban cards based on parametAuto-trigger pull demand, pick requests & start / completion

Set p Step 6 Update Prod ction


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Setup Step 6 :Update Production

Update production to reflect changes in production plan and

Setup Step 6 :Kanban Cards


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Setup Step 6 :Kanban Cards

Kanban Card a signal that there is a product shortageClick Replenish to replenish the component.

Integrated Kanban Management


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Integrated Kanban ManagementImprove Inventory Turns and Labor Efficiency

Inventory

Point of Supply Poin

Production

Supplier

PullSequence KanbanPlanning

KanbanExecution

Flexible Pull Sequencedefinition supporting singlecard, dual card, and non-replenishable kanbans

AutomaticaltransactionsSchedule, M

Simulate and compare multipledemand scenarios

Generate new Kanban cards andautomatically cancel outdated cards

Pull Plan Exe

Signal via electronic visual cues

Feeder Plant

Setup 6 : Component Pick Release (op


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Setup 6 : Component Pick Release (op

FML uses Kanban for Component replenishment.Can use CPR for slow moving or randomly used componenalternative.

Setup 7: Define Scheduling Rules


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Setup 7: Define Scheduling Rules

Used by Line Scheduling Workbench (see later).

Setup 8 : Setup Sequencing Constraint


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Setup 8 : Setup Sequencing Constraint Sequencing is used to consider your demands and determine a sequence for building assembly items. Define attribute

them into rules for the assigned production line. Attribute = characteristic of your demand Constraint = restriction enforced on an attribute. E.g Colour. Red first and then black. Sequence assemblies based on Rule = grouping of prioritized constraints for the attributes.

Setup 9 : Setup Flow Exec Workstation


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Setup 9 : Setup Flow Exec Workstation Sequencing attributes, sequencing rules. Assign the sequencing rule to the production line Define the workstation parameters /preferences for look and feel and for available options HTML and Forms versions of Flow Workstation exist. We will focus on HTML version.

PROCESS FLOW : 1 : Demand


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PROCESS FLOW : 1 : Demand

Sales orders and/or Planned Orders from ASCP. SO : 6664

PROCESS FLOW : 2 : Create Flow Sch


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Open the Line Scheduling Workbench ; Enter criteria, Create Flow



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Flow Schedules have been created. Click Details.



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Note the individual flow schedules and the link to SO 66646 The flow schedules take into account the sequencing rules/



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Can check component availability against the flow schedule



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Sequencing tasks can be used to create flow schedules als A concurrent program creates the flow schedules on submi Uses the defined sequencing rules and constraints Options : Resequence existing schedules or create new sc

PROCESS FLOW : 3 : Initialize Workst


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PROCESS FLOW : 3 : Initialize Workst

Select org, line and op and specify any optional selection c Note : This assembly has 5 line ops : MBRD, CASE, DRV, T

PROCESS FLOW : 4 : View Schedules


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PROCESS FLOW : 4 : View Schedules

Schedules can be seen in work queue mode as below or u(scanned or entered). Controlled by the preferences defined

PROCESS FLOW : 4 : View Schedule D


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Drill into Schedule Number to see details - events tab sho



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Click on Event Seq Number to see the event details..



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Drilling into Events also shows detailed instructions, diagra



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Instructions tab shown below. Details of instructions, diagrams, specifications etc



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Components tab shown below. Shows components for all th



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Resource Tab shows resources linked to the events for thoperation and schedule.



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General details for the line schedule



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View any custom parameters used for the line schedule.

PROCESS FLOW : 5 : Update Schedul


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Update any details if required.

PROCESS FLOW : 6 : Complete Line O


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Click on Express Complete Line Operation Button for flow sDJ877265, op MBRD (1stop)



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This line op requires some mandatory quality data to be up Mandatory quality collection data can be specified for any o



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Enter the quality data where required.



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Now click on apply after quality data entered.



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Note the completion message and the updated work queue. The assembly has been moved to the NEXT operation. NO material trans When you complete the LAST operation, you have option to complete the



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To see impact of the op completion, query the next OP - CA



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The assembly has been moved to the next op as can be se Note : can set parameters to display different buttons for ea

PROCESS FLOW : 7 : Process All Ope


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Complete Line op CASE moves assembly to Op DRV.



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Complete Line op DRV moves assembly to Op TEST.



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Complete Line op TEST moves assembly to final Op PACK

PROCESS FLOW : 8 : Complete Sched


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There are 2 options for Assembly Completion :- Complete Schedule : Info or review required (html version of work orde- Express Complete Schedule: Automatic completion using defaults



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Stage 1 :Select complete schedule option. Options to amend qty and specify alternate routings at this

PROCESS FLOW : 8 : Complete SchedSt 2 E t lit d t d if l t d i l b f l t d i l


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Stage 2 : Enter quality data and specify any lot and serial numbers for lot and serial cCan subsitute, remove components. l removed some components for ease of use.


St 3 T ti l t d li ki fi i h C


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Stage 3 : Transaction completed on clicking finish.Componbackflushed. Assembly completed into inventory. Flow Scheremoved from work queue. DJ877265 no longer seen here.


C th bl l ti t ti b l


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Can see the assembly completion transaction below.


Note that you can go to complete schedule directly for the flow schedule a


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Note that you can go to complete schedule directly for the flow schedule aassembly through all the operations.


C f i f W k d L C l ti l


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Can use forms version of Workorder Less Completion also

PROCESS FLOW : 9 : Scrap Assemblie

Can add option to scrap assemblies via the parameters


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Can add option to scrap assemblies via the parameters This follows same process as work orderless completion

Technical Information:Q1: Is there a public api for completing flow schedules?


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Q1: Is there a public api for completing flow schedules?

A1: Insert records in MTL_TRANSACTIONS_INTERFACE and set transaction source to flow schedThen run inventory manager to process the completion. Will mimic work orderless completion acomponents.

Q2: How do we display additional details for completing the work in the custom property region of FWorkbench?

A2: Use the following:Package Name: FLM_EXECUTION_UTILProcedure Name : GET_ATTRIBUTES

Q3: Is there an API to import Flow Routing, Standard Line Operations, Standard Events & Events R

A3: No. Enter manually or use dataloaders. There is an ER to create api for this:Bug 5460084: CREATE RESOURCES, STD OPERATION, ROUTING EXTERNALLY USING A

Technical Information:Q4: What table is used to store Flow schedules ?


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Q4: What table is used to store Flow schedules ?

A4: WIP_FLOW_SCHEDULES.

Here are other important tables :FLM_KANBAN_SUMMARY summary of kanbansFLM_MMM_PLANS - Mixed Model Map PlansFLM_MMM_LINES - Mixed Model Map LinesFLM_MMM_OPERATIONS - Mixed Model Map OperationsFLM_SEQ_RULES Sequencing rulesMRP_AD_FLOW_SCHDS stores details about deleted wip flow schedules

Technical Information:Q5: What apis are available for FLM?


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p

A5: There are 3 apis :

1. Custom Kanban Quantity Calculation API : used to calculate kanban size and qtyPackage Name: MRP_CUSTOM_LINE_SCHEDULEProcedure Name: CUSTOM_SCHEDULE

2. Custom Schedule API : for extending the available line scheduling algorithms.Package Name: MRP_CUSTOM_LINE_SCHEDULEProcedure Name: CUSTOM_SCHEDULE

3. Flow Schedule API : create, update, delete, retrieve, lock, schedule and unlink order lines oPackage Name: MRP_FLOW_SCHEDULE_PUB

Procedure Name: PROCESS_FLOW_SCHEDULE

SummaryWhat we covered today


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Looked at concepts of FLM.

Looked at how to setup FLM.

Looked at the basic process flow

using screenshots.

Considered basic apis and tables.

Flow ManufacturingSupport Lean Practices to Reduce Cycle Time & Waste


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ValueStreamMapping

Define and associatestandard processes w/configurable models

Add alternate pathsand rework loops

Add standard events,associate with options

Identify TQC andvalue-add events

Associate workinstructions withoptional events

LineDesign

Calculate line andoperation takt andrequired resources

Highlight imbalancesbased on optionsplanning percentages

Reorganize events intobalanced operations

LeanPlanning

Kanban planningbased on optionplanning percentages

Demand leveling andsmoothing by line rate

Order promising byline rate

Collaborative planningfor VMI and consigned

Inventory optimizationfor postponement

LeaExe

Ka

Cosecoatt

Fesyjus

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Opdeins

To ask a qphone line

your phon


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Questions & Answers

your phon

To ask a q

use the Q

top.

Your ques

aloud in th

received.

Question

asked on

Support C

Top Articles and Community Links


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Mfg WIP Advisor Webcast 2013 1204

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