מפת הדרכים של מוצר ה-OPM , שדרוגים, התקנות של R12 וסיפורי לקוח

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R12 Update For Israel Process SIG MeetingKaren Theel - Senior Strategy Director, Manufacturing

© 2011 Oracle Corporation – Proprietary and Confidential

“Manufacturers have been plagued with islands of systems

and processes that are isolated within sites or departments. Such silos don’t allow for easy collaboration across the manufacturing value chain—internal departments like sales, operations, and marketing, as well as partners and customers—as

manufacturers strive to make quality products correct the first time and on demand in today’s highly competitive marketplace.” -- Demand Driven Mfg (C. Masson, A. Smith, S. Jacobson) Jan

‘07

Multiple Plants w/ Different Systems

Factory

Automation

Homegrown /

3rd Party MES

Quality

/ SPC

Maintenance

/ Service

Multiple Contract Mfgrs

Corporate

Customer

Relationship Mgmt

Supply ChainManagement

Business

Intelligence

Enterprise

Resource Planning

DisconnectedDisconnected

“Manufacturers have been plagued with islands of systems

and processes that are isolated within sites or departments. Such silos don’t allow for easy collaboration across the manufacturing value chain—internal departments like sales, operations, and marketing, as well as partners and customers—as manufacturers strive to make quality products correct the first time and on demand in today’s highly competitive marketplace.”

Today’s Operations RealityLack of Visibility, Flexibility, and Insight with Disparate Systems


What are Mfg companies investing in?….


Manufacturing Applications Continued Investment

EBS 12 EBS 12.1 EBS “Post 12.1.3”

•• Rapid ReturnRapid Return

•• Standardize & SimplifyStandardize & Simplify

ThemesThemes

•• Think GloballyThink Globally

•• Work GloballyWork Globally

•• Manage Systems GloballyManage Systems Globally

Global Business ReleaseGlobal Business Release

�F o u n d a t i o n f o r t h e f u t u r e

•• Ongoing InnovationOngoing Innovation

•• Lifetime SupportLifetime Support

Key MessagesKey Messages

2006 2007 2009

Preview Today

2010 2011

EBS 12.2

ThemesThemes

•• Improved TechnologyImproved Technology

CurrentCurrent FutureFuture


New in 11i.10Base Differentiators…New in R12…

• Collaborative, rules-based recipe development

• Ingredient and process variability management

• Multiple cost methods

• Real-time WIP visibility

• Lot traceability

• Co-products & by-products

• Shelf-life and status control

• Potency / grades

• Integrated process quality workbench

• Manufacturing scheduler with process production

• Electronic signatures and records for 21 CFR part 11

• HACCP quality test points

• Graphical recipe designer

• Lot specific costing

• Computer-aided formulation

• Electronic records and signatures document control

• Enhanced customer quality specification matching

• Mass quality control result entry

• Enhanced co-product planning (via advanced planning integration)

• Environmental testing

• Multiple drum receipt with automatic lot numbering

Evolution of Oracle Process Manufacturing

• Common inventory system with process attributes

- Pricing on secondary UOM

- Item revisions

- Move orders

- High level reservations

• Common item master

• Least cost formulation

• MES for Process Manufacturing

- Operator-centric workbench

- Dispensing / pre-mix

- Device integration

- Electronic MBR / CBR

- Non-conformance tracking

• One-step electronic signature

• Planning complex routings

• Manufacturing Operation Center


Order Management Procurement ASCP

OPM Recipe / Quality

OPM

Costing

OPM

Production

BOM /

QualityCostingWIP

OPM

Inventory

Discrete

Inventory

Single Source of Truth for Inventory Availability Advanced Inventory Management

Order Management Procurement ASCP

OPM Recipe / Quality

OPM

Costing

OPM

Production

Oracle Inventory

BOM /

QualityCostingWIP

• Single Inventory Model

• Process features

include:

• Tracking in two units

of measure

• Grade

• Expiration/ Maturation

Dates

• Material Status

• Enhanced inventory

allocation rules

• Indivisible lots

• Support for “child lots”(replace “sublots” in OPM)


Model Actual Scenario of Shop FloorImprove inventory visibility at each stage of the Supply Chain

• Reservation supply

to assure inventory

meets customer

needs

• High level

• Detail Level

• Model plant areas

so that stock is

readily available

• Dispensing Locations

• Staging Locations

ProductionOperator

Materials ManagerProductionSupervisor

DispensingOperator

Review andApprove Schedule

Schedule FPO / Batch& Reserve Materials

Dispense Ingredients with

Detailed Reservations

Move IngredientsTo Staging Location

ReverseDispense Ingredients

Complete & Close Batch

Log Nonconformances

Review ControlBatch Record

Consensus forecast and

production plan

Lock Operation, Follow PI,

Execute Tasks


Summary of Functionality Gains for Process Users

• Central item master

• Organization specific attributes

• Leverage Product Data Hub

• Vendor-Managed and Consigned Inventory

• Warehouse Management Additional License

• Mobile Supply Chain Applications Additional License

• Flexible account mapping with Subledger Architecture

• Additional Lot Management Transactions via MSCA

• Lot Merge

• Lot Split

• Lot Translate

• Flexible Attribute Definition

• Attribute Inheritance

• Reservations and Move Orders for Production Batches

• Unconstrained ASCP replace MRP


Container and LPN* Support

• Supports infinite nesting levels

• Perform complex moves via a single scan

• Fully integrated with ASNs

Improves Efficiency,Accuracy, and Tracking

Barcode Support

• Record transactions at the point of use via RF Devices

• Eliminate data entry errors by scanning instead of typing

Reduces Cycle Time & Improves Accuracy

Single Unique Numberfor All Information

Multiple Packages and Products

=

*License Plate Number

RF, Barcode and License Plate SupportPerform Complex Inventory Transactions

© 2011 Oracle Corporation – Proprietary and Confidential 10

LPN Support in OPM Desktop Forms Streamline operator actions through online support of container

management

• Available with WMS

• Added for:

• Item Reservations for

Process organizations

• Select Available Inventory

• Batch Material

Transactions form

• Item Samples

• Sample Group related

forms

• Delayed LPN Entry added

for

• Quality Samples


11

ATP

Check

GOPDay 1 Day 2

• Multiple facilities

• Which plant makes what products and when

• Pre-builds based on capacity shortages

• Alternate facilities, suppliers and processes

Day 3

Production Schedule Org 1

8am 12pm

• Schedule a single facility

• Sequence Production to meet demands on this facility

• Account for detailed production constraints and come up with an executable schedule

4pm

PS – Production Schedule Org 2

PS – Production Schedule Org 3

Constrained dependent demands

independent demands

planned orders

ASCP – Production Plan PS – Production Schedules

Production Plan Org 1, 2, and 3

Execution work orders

Process batches, and

Lots scheduled detailed

activities

Integrated Manufacturing Planning & SchedulingUnconstrained* Planning Replaced MRP

*Constrained planning require additional license


Plant to Enterprise StrategyMultiple options for increased shop floor visibility

ERP + Integrated MES

Detailed Instructions & SOPs, Nonconformance Mgmt., Electronic MBR and CBR, Mobile, Labeling,

Device Integration

Oracle ERP

Integrated Oracle MES

Devices

Electronic records, process-centric, low-med shop floor

automation, standardization and data visibility across plants

Integration

ERP + Integration other MES + MOC

ISA 95 based Manufacturing Hub with Devices Integration

Oracle ERP

Legacy MES

Devices

Electronic records, decentralized plants, highly automated, accept costs of maintenance of interfaces

Manufacturing Hub / Analytics

Integration

Existing Manufacturing Suite

Oracle ERP

Paper batch records, material-centric, minimal automation and manual

data entry

© 2011 Oracle Corporation – Proprietary and ConfidentialThe above reflects Oracle’s current development plans which are subject to change at any time

Oracle Manufacturing Operation CenterReal-time Performance Visibility

New Features in R12.1.2:

•EBS R12.0.6 Adapters

•Event Management Framework

Automation& Process

ControlSystems

ERPSystems

Users

PLC CNCMachines

DCS SCADASystems

AdvancedProcessControl

HumanMachineInterface

- MES- Quality- Cost Mgmt…

ManufacturingOperationsData Model

ManufacturingOperationsData Model

Role-BasedDashboards

Contextual-izationEngine

Corporate BI

Cross-PlantKPIs

HistoricalTrends

Plant-SpecificKPIs

Real-TimeUpdates

Device-Generated Data

Production ActualsSchedules

Item Master Data

ProductionManager

Plant Mgr /VP of Mfg

MES Shop Floor Communication Drivers

© 2011 Oracle Corporation – Proprietary and ConfidentialThe above reflects Oracle’s current development plans which are subject to change at any time

- Red-yellow-greenindicators

• 55+ KPIs, 90+ measures, reports and alerts out of the box

• Pre-built role-specific dashboards

• CO2 emissions tracking with Sustainability Sensor Data Management (SSDM) – 12.1.3

• Graphical views

- Trend charts

- Graphs

- Tables

• Embedded best-practice calculations and KPIs

• Analytic workflows to drive actions

• Drill-downs into details forroot-cause analysis

• Leverages OBIEE+

• Configurable and customizable

Role-Based Dashboards Deliver Performance Measures by Responsibility


System Automation & Control

� Deliver Real-Time Shop Floor Visibility to Multiple Layers of Management

� Reduced TCO / Complexity via Integrated Mfg Mgmt & Production Execution

MESMES

ERPERP

Corp Mgmt

Shop Floor Control

Production MgmtProduction Mgmt

Process Engineer

• Manage recipes & advanced process instructions

Production Supervisor

• Create & manage batch status

• Log non-conformances

Dispensing / Prod Operator

• Touch Screen User Interface

• Pre-weigh designated ingredients

• Process batch operations

Operator

• Work from dispatch list

• Record transactions, qualityinfo, work completion, and time

• View work instructions andcomponent info

• Report production exceptions

Supervisor

• Review & resolve exceptions

• Monitor shop floor progress

MES for Discrete MfgMES for Discrete Mfg MES for Process MfgMES for Process Mfg

Optimize Manufacturing OperationsOracle Manufacturing Execution Systems (MES) for Discrete & Process Mfg


Process MES Operations

• Process Engineer/ Formulator

• Manages recipes and advanced process instructions

• Production Supervisor

• Creates and manages batch status

• Logs nonconformances

• Dispensing

• Pre-weighs designated ingredients

• Production Operator

• Processes batch operations

ProductionOperator

ProcessEngineer

ProductionSupervisor

DispensingOperator

Create Recipe

Add New Enhanced Process Instructions

Create/UpdateValidity Rule& Review

Master Batch Record

Schedule Batch& Reserve Materials

Dispense Ingredients

Lock Operation, Follow PI,

Execute Tasks

ReverseDispense Ingredients

Complete & Close Batch

Log Nonconformances

Review ControlBatch Record


Facilitate Compliance with Operator WorkbenchTouch Screen enabled

Operator is stepped through instructions and tasks

Direct link to SOPs

Configurable acknowledgement: -Optional

-Required Acknowledgement

-E-Signature(s)

One Click Access to Transactional Forms: -


Read Values Read Values Direct from Direct from

DevicesDevices

Generate Generate

LabelsLabels

Multiple methods Multiple methods

supportedsupported

Dispensing / Pre-WeighImprove Accuracy & Compliance While Reducing Risk

• Improve accuracy by

removing human interaction

• Enforce compliance

- Configurable level of control on process instructions

enforce best practices and

regulatory compliance

• Reduce complexity & risk

- Simplified task- based operator interface

- Consolidate systems


Nonconformance ManagementCapture and Record Deviations

• Access directly from batch

• Capture and document nonconformances / deviations

• Configurable criticality

- Informational

- Resolution required prior to completing batch or step

- Configurable e-signatures

• Included in control batch record

- Critical nonconformances must be reviewed and signed prior to close of the batch

- Leverages Oracle Quality

“Any deviation from the written pro-cedures

shall be recorded and justified.” --

21 CFR Part 211.100, Written procedures

for deviations


Group Multiple Batches for Mass ActionsIncreased productivity for batch flow transactions

• Grouping multiple

batches for a user

selected criteria

• Simple and user friendly

window to perform

select action on a group

of batches

• Mass transact batches

for all Batch actions

• Release, Complete,

Close, Un-Release,

Re-Open, Revert to

WIP, Auto Detail

Check off Check off batchesbatches

Select Select ActionAction

Execute Execute ChangeChange


Gain Visibility into Real CostsLanded Cost and Cost Management Visibility

Kansas City US Port

Vessel CarrierHK PortShipment to HK

Customer

$100 $2 $3 $20 $3 $2 $140

China Manufacturing

Buyer

An additional 40% is added on to the purchase price

$5Duties

$5Broker Fees

Total Landed Cost

Issue PO

Capture extended supply chain costs (freight, insurance, duties, taxes, etc.) and attributes them back to the products which incurred them

• Costs can be estimated during PO creation and receiving

• Actual costs calculated when invoices arrive to identify variances

• Receiving estimates and any variances automatically update inventory valuation and accounting


• Robust cost reporting capability with drill-down to costing data from

summary to cost component and item level details with multiple views

• Granular view of the costs, enables management to control costs and

measure efficiencies

Costed Indented Bill of Materials ReportProvides sound basis for performance management, control by

exception reporting and establishing product margins


SEESEE ITIT TRY ITTRY IT KNOW ITKNOW IT DO ITDO ITUser User

ModesModes

Financials• Payables

• Receivables

• General Ledger

• Assets

• Internet Expenses

• Advanced Global Intercompany

System

• E-Business Tax

• Subledger Accounting

• Bank Account Setup/Maintenance

Procurement• Purchasing

• iSupplier Portal

• iProcurement

Distribution • Inventory

• Order Mgmt

• Shipping Execution

Projects• Project Costing

• Project Mgmt

• Project Resource

Mgmt

Applications Technology• Applications Mgmt

• Forms Personalization

Manufacturing• Discrete Bill of Materials

• Shop Floor Management

• Work In Process

• Discrete MES

• Discrete Quality Mgmt

• OPM Product Development

• OPM Process Execution

• OPM MES

• OPM Cost Management

• OPM Regulatory Mgmt

1,575 Pre1,575 Pre--delivered Topicsdelivered Topics

Self-Running Demo Interactive Simulation Testing for Competence Context-Sensitive Help

Drive Greater End User ProductivityPre-Built End-User Documentation


Drive Greater End User ProductivityBetter Document Publishing

Oracle Business Intelligence Publisher for Oracle E-Business Suite

24


Future Proposed Projects

• Technology Enhancements:

• On-line patching

• OA Framework enhancements

• OSP / Contract Mfg

• PLM Integration –

• PLM for Process for Food and Bev

• Analytics

• Continued investment in MOC

• Manufacturing BI

• Quality BI

• Mobile Transactions for Quality

• OPM device integration to non-TCP/IP devices


OPM R12 Customer update

Live OPM – 68

New Installs – 60

Upgrades – 8

• 4 migration

• 4 re-implement

Current R12 Implementations:

• New R12 in progress - 12

• Upgrading - 20

Last updated 1/20/2011


OPM Customer Migrations/Re-implementations

• Migration

• Not making major changes

• Currently 3 have migrated using OPM scripts

• For 2010 – 9 are currently in the process of upgrading

• Re-implementation reasons

• Changing formula structure, add recipes

• Lessons learned from initial set ups in GEMMS

• Bringing up foreign operation

• Changing chart of accounts (advised by consulting firm)

• Simplify item structure

• Current hardware wouldn’t support production & running

upgrade scripts


Oracle Migration Team

• Proposed Calls

• Oracle Development group

• Support group

• Strategy Product Management

• Customer

• Before you begin the Migration Process

• Arrange for your call

• Contact

[email protected]

914-524-1606


OPM 11.5.10 to 12.1 Migration DocumentsMetalink note 376683.1

These documents are available to help customers understand the migration process and to help guide them through the process.

• OPM Migration Overview and Business Needs GuideThis document contains an overview of the OPM Migration process and the business needs that are met by this process.

• OPM Migration Best PracticesThis document contains helpful tips to help ensure that the migration process proceeds as smoothly and as efficiently as possible.

• OPM Migration Reference GuideThis document provides information on how the 11.5.10 Oracle Process Manufacturing data is mapped to the converged R12.1 Oracle Inventory model, and the User Interface and options available for the mapping of that data.

• OPM Migration ChecklistThis document lists all steps and patches needed to migrate data from Oracle Process Manufacturing Release 11.5.10 to 12.1. in the order in which they must be applied.

• OPM Migration Messages and Technical ReferenceThis document lists the messages that can be logged during the running of the data migration and the actions required based upon those messages. The names of the individual migration scripts and Data Mapping tables are also available in this document.

The Checklist and Best Practices documents are live documents and will be updated as needed.


R-12.1 Check List 1.Preparation

Review the Oracle Process Manufacturing (OPM) Migration Reference Guide – Release 11i to

12.1

Review the Best Practices Guide for OPM Migration from 11i to R12.0/12.1

Please see Metalink note# 376683.1 for OPM Migration related documents.

NotesNotesNotesNotesDate Date Date Date CompletedCompletedCompletedCompleted

Action OwnerAction OwnerAction OwnerAction OwnerActionActionActionAction

2.Pre-Migration

5750051Above patch fixes data corruption issues with Items that would affect migrating OPM entities.

ALL Customers

Install the latest Datafix patches.

NotesNotesNotesNotesDate Date Date Date CompletedCompletedCompletedCompleted

Action Action Action Action OwnerOwnerOwnerOwner

Applicable Applicable Applicable Applicable Patch and Patch and Patch and Patch and CommentsCommentsCommentsComments

ApplicabilityApplicabilityApplicabilityApplicabilityActionActionActionAction


Go-Live USANA

Company Overview• USANA Health Sciences, Inc. develops and manufactures high-quality

nutritionals, personal care, energy, and weight management products that are sold directly to preferred customers and associates in nearly 15 countries worldwide.

• Employs over 900 people worldwide, including approximately 630 people at the corporate offices in Utah

Challenges • Support continuous improvement in operational efficiency across the

health sciences company’s business

• Unify discrete and process manufacturing inventories to enable complete visibility of inventory enterprise-wide

• Facilitate voluntary compliance with U.S. Food and Drug Administration (FDA) and Australia Therapeutic Goods Administration (TGA) guidelines on nutritional supplements

ORACLE PRODUCTS

– Inventory Management

– Advanced Supply Chain

Planning

– Mobile Supply Chain

Applications

– Discrete Manufacturing

– Process Manufacturing

– Manufacturing Execution

System

– Enterprise Asset

Management (eAM)

– Quality

– Production Scheduling *

– Advanced Pricing

Under NDA


Usana Migration ExperienceGo Live Date: November 2009

Migration from 11.5.10 to 12.1.1

Total DB Downtime: Actual DB downtime was under 48 hours

Overall Impression: Happy with the overall process and the time that it took to be completed. Found migration documents to be very helpful – especially the Migration Checklist.

Volume Of Data• 13 companies/Sets of books

• 42 Warehouses (mapped to subinventories)

• 12,000 Items

• 114 Open Batches

Timings• SLA configuration took approximately 4 hours.

• In-line migration patch took roughly 15 hours for English and over 40 hours for 5 other languages

• OPM Data Transformation took about 30 minutes

• OPM Financials Data Transformation took just under 12 hours


Cabot Migration ExperienceGo Live Date: November 2010

Migration from 11.5.10 to 12.1.1

Total DB Downtime: Pending

Bugs During Process:

8 Total

• 5 NAB – Did not follow checklist, setup issues

• 1 Fix – Migrating Forecasts

• 1 ER – Scripts to Check for ISOs and Internal Transfers

• 1 Doc bug

Volume Of Data• 5 Companies/Sets of Books

• 20 Organizations

• 22 Warehouses (mapped to subinventories)


Complete ChoiceChoose Your Next Steps