Principal Consultant Sid...

Oracle FlowManufacturing

Sid PereraPrincipal Consultant

Oracle Manufacturing SolutionIntegrated

IntelligenceCost

Analysis Productivity

Planning

• Planned Orders• Schedule Changes• Component

Substitutes• Resources

Substitutes

ProductLifecycle

MgmtWarehousing

/ Transportatio

n

Service

AssetMaintenance

• Demand Schedules• Sequencing• Configured Order

Lot / Serial Genealogy Tracking

Quality Management

Discrete Flow

Process Lot-Based

CTOETOMTS

Mixed Mode

• Production Status• Material Availability• Mfg Capacity• Schedules/Changes• Ship Notices• Invoices/Payments

EnterpriseShop Floor

MES APIs,Direct

Access

Customer

PartnerCollaboration

Contract Mfgrs

Real-TimeWIP Visibility

Contract Mfgrs

Model ShopFloor

Suppliers

Suppliers

Analyze AdjustSample

What is Flow Manufacturing?

● More than a module - its a “new way of life”● Dedicated assembly lines supporting product families● Mixed model production - lot size of one● Balanced line ensures smooth flow and optimum

resource utilization● Demand driven line and cell schedules● Pull manufacturing● Point-of-use kanban replenishment

Oracle Flow Manufacturing Solution

1. Plan for Customer Demand (Configured Products)

2. Design for Balanced Operations

3. Schedule and Sequence for Efficiency

4. Communicate and Complete Production

5. Plan for and Execute Kanban Management

Enables you to:

Plan for Customer Demand

● Complete Integration with Oracle Planning Products, Planning Workbench

● Product Family Definition and Planning▪ Model Definition

▪ Option Class with Planning Percent▪Optional Items with Planning Percent

● Two-level Master Scheduling

Techniques used

Production Planning

● Forecasts at family level● Explode family forecasts to members ● OR - plan based on unconsumed family forecast● Consume family forecast with member demand● Check ATP by product family or individual item

Product FamilyLaptops

Envoy Presidential

30%

Envoy Multimedia

50%

Envoy Sentinel

20%

Forecast & Consume

Sales Orders







Enables you to:

Seq. Task

Valu

e A

dd?

Setup

Mac

hine

Labo

r

Dyn

amic

/ Sta

tic

Qty

Int\E

xt

Mac

hine

Labo

r (s

ec)

Move Quality Info.

Description

Install Red Capacitor1 0 1 To Chip Dept Ensure snap

to board

Move to Chip Dept2 600 600

Install Yellow Chip3 0 1 To Inspection Right of Red Cap.

Move to Insp/Test4 600 600

Machine Time = 1800 Sec or 30 Min.

Inspect - Test5 1 To FGI Warehouse

Move to FGI Warehouse6 600 600 To Shipping Compare Order to

Product

Labor Time = 1803 Sec or 30.05 Min.Elapsed Time = 1803 Sec or 30.05 Min.

Work Content = 3 Sec!!!

0

Sequence of Events DocumentDesign for Balanced Operations

Design for Balanced Operations

Example Processes, Sequence of Events, & Operations

Welding Assembly Painting

mount surface

s

weld edges

boltmoto

r

sealend

s

attach legs

cleansurfac

e

paintsurfac

e

polishsurfac

e

PROCESSES >

SEQUENCEOF EVENTS >

Production line

Op 10 Op 20

Op 30

Op 40

Op 50

LINE OPERATIONS >

Complex Bill - high maintenance

Flat BOM

Concurrent Process Engineering

Design without considering the factory process

Visual Network Routings


Other Objectives

▪ Graphical Line Designer ▪ Network Routings

● Sequence of work events● Network of operations

▪ Alternate Paths▪ Feeder Lines▪ Drag and Drop

How Oracle Supports Them


Example

Design for Balanced Operations Graphical Line Designer

Primary, Alternates, Rework, Subassembly Feeder, Etc.

Design for Balanced Operations Graphical Line Designer

Sequence of Events

● Mixed Model Map Workbench▪ Analyze Different Scenarios

▪New Product Introduction▪Changes in Demand▪Process Improvement▪Bottleneck Resolution

How Oracle Supports It

Design for Balanced OperationsHow do I balance the line?

Design for Balanced Operations How do I balance the line?

Example Processes, Sequence of Events, & Operations

Welding Assembly Painting

mount surface

s

weld edges

boltmoto

r

sealend

s

attach legs

cleansurfac

e

paintsurfac

e

polishsurfac

e

PROCESSES >

SEQUENCEOF EVENTS >

Production line

Op 10 Op 20

Op 30

Op 40

Op 50

LINE OPERATIONS >

Mixed Model Map


Line Balancing Mixed Model Map Workbench


Mixed Model Map Workbench Bottleneck resolution

Mixed Model Calculations

● Line Takt Time = ((Mts/Day)x No of Dem Days))/Total Demand

● Machines Needed= MC Wtd Time/Opn Takt Time

● MC Assigned=Tot No of MC (In the dept)● Labor Needed= Lbr Wtd Time/Opn Takt

Time● Labor Assigned=Tot Av (In the dept)







Enables you to:

Line Scheduling

Line Scheduling

● Schedule production based on customer orders (or planned orders)

● Sequence production based on model mix to maximize line utilization

● Smooth demand fluctuations using demand fences

● Review material and resource availability for product family schedule

Objectives

Scheduling Algorithms

● No Level Loading– Scheduled by “Scheduling Criteria”– Scheduled until capacity is reached

● Level Daily Rate– Total demand is spread evenly across

scheduling horizon● Mixed Model

– Same as Lvl Daily Rate– Follows a production rule pattern for mix

Sequencing Criteria

● Order Entry Date● Order Priority● Order Promise Date● Order Request Date● Order Scheduled Date

Sales Orders

Planned Orders

Planned Order Due Date

Line Scheduling

● Sequence based on user-defined priorities● Schedule to line rates● Balance production lines● Schedule mixed-model production● Execute directly from sales order demand

Line Scheduling Workbench

Line SchedulingSales Order Demand

Product B Product B Product BProduct A Product A Product A Product A

SO 1

1-JUN

Priority 2

SO 2

2-JUN

Priority 1

SO 4

4-JUN

Priority 2

SO 5

5-JUN

Priority 1

SO 3

3-JUN

Priority 3

Algorithm = No Level Load, Criteria = Order Priority, Date

1-JUN 2-JUN 3-JUN 4-JUN Unscheduled

Line Scheduling

SO 1SO 2 SO 4

SO 4SO 5 SO 3 SO 3SO 1

Line Capacity

● Schedule only 4 days of production

Algorithm = Level Daily Rate (Spread Demand Evenly)


Line Scheduling

Line Capacity

Product A

Product B

Product A

Product B

Product A

Product B

Product A

Product B

● Same criteria options to sequence orders

Algorithm = Mixed Model Scheduling (Production Rule Pattern)


Line Scheduling

Line Capacity

● Sequence Based on User-Defined Priorities● Execute Directly From Sales Order Demand● Schedule Mixed-Model Production● Balance Production Lines● Feeder Line Synchronization● Supplier Synchronization● What Ifs and Simulations

Techniques Used

Schedule and Sequence for Efficiency

36

User Defined Sequencing Rules

Selected data attributes applied to constraints

37

Constraint Sequencing for Efficiency

38

Schedule Sales Order or Planned Order Demand

Line Scheduling Work Bench

39

Schedule Sales Order Demand

LSWB –Demand dates and Production dates

40

Mixed Model Schedule Summary

LSWB –Balanced Mixed Model Production

41


LSWB –Balanced Mixed Model Production

42

Mixed Model Schedule SummaryLSWB –Detailed schedules with Sales Order reference

(Different Item)

43


Capacity Check

44


Capacity Check







Enables you to:

● Define Pull Sequences

● Calculate #of Cards / Kanban Size

● Kanban Requirements Simulation

● Generate Non-Replenishable Kanbans

● Automate Transactions - Generate Requisitions

Techniques used

Plan for and Execute Kanban Management

Pull Sequences

Production line

Op 10 Op 20

Op 30

Op 40

Op 50

raw in processloc 1 loc

5loc 4

loc 2

supplier s1 line l1

intra-org r1

inter-org i1

raw in processloc

3

supplier s2

supplier s3

item A

item B

item A

item C

item D

item D


Replenishment Chain

Replenishment ChainView by: Supplier, Buyer, Location

● Replenish Internal Kanbans

– Stores Move (Intra-Org)– Production

● Replenish External Kanbans– Supplier Kanbans

● Aggregate Kanban Signals– Move Order (Inter-Org)

● Non-replenishable Kanbans

Kanban Execution Signals


52

Supplier Kanban ExecutionPurchase to Build – Component demand and Production Sequence communicated to suppliers.







Enables you to:

● Flow Workstation▪ Communicate Schedule▪ Convey Work Instructions (OMS)

● Work Orderless Completion▪ Extremely Lightweight Entity▪ No Pre-exploded Bills and Routings▪ Substitutions and Changes▪ Management of Engineering Changes▪ Serial / Lot Control, FG and Components

● Scrap Reporting● Quality Collection Integration

Techniques Used

Communicate and Complete Production

Flow WorkstationPaperless Communication of Production Schedule - work instructions, OMS, components, resources

Flow WorkstationPaperless Communication of Production Schedule - work instructions, OMS, components, resources

Attachments

Work Order Less Completion

Work Order Less Completion

No Pre-exploded Bills and Routings, Management of Engineering Changes, Substitutions and Changes, Serial / Lot Control, FG and Components, Scrap,

Quality Integration, Mobile Support

Summary

Oracle Flow Manufacturing

● Complete Flow Infrastructure– Flow and ERP Data Model Integration– Demand Management– Line Design and Balancing– Line Scheduling– Production Execution– Kanban Planning and Execution

Know More. Do More. Spend Less.

Principal Consultant Sid...

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