TRAINING DAY

1
TRAINING DAY August 11,2006 Larry Gray
lgray_at_darc.com
2
Using 11i10 Oracles Manufacturing Execution
Capabilities and Quality
Integration
Larry Gray DARC Corporation Principal
Consultant Supply Chain Practice
3
Value of Quality WIP Integration

• Quality and Operational Disconnects
• Secret/Closed PC based systems
• Paper based forms and file cabinets
• Out-of-date information and lost and missing
  paper
• Highly paid staff involved in clerical duties
• Audit trails are based on memory
• Data accuracy in doubt
• Multi Org problems and collaboration
• Supplier problems and corrective actions

4
(No Transcript)
5
Value of Quality WIP Integration

• Quality Programs and Closed Loop CAR
• Total Cost of Quality
• Six Sigma - DMAIC
• Continuous Process Improvement
• ISO 9000
• Zero Defects
• Non Conformance
• Corrective Action

6
Value of Quality WIP Integration

• WIP to QA Process Flow Orientation
• Configurable to your business flow
• Mandatory Quality
• Parent/Child Plans
• Templates for Non Conformance and Corrective
  Action
• Flexibility Future Changeability
• Workflows and approvals
• Electronic Records and Signatures

7
Configurable to Your Business Flow

• Quality triggers are very flexible
• Quality actions are also flexible
• Data input requirements vary per need
• Resolutions are varied and complex
• E-Records and Signatures at critical business
  events
• Processes evolve and improve
• Timely feedback is necessary
• Manage exceptions

8
(No Transcript)
9
Mandatory Quality Input

• Transaction Based Tool for requiring quality data
  input built-in for your process (11i10 36)
• Triggers are available on mobile device also
• Trigger is configurable to your process
• Data entry is real-time
• More consistent processes are guaranteed
• Work/Job may not proceed until QA complete
• Security is part of the process
• Background transactions can be used very easy

10
Parent/Child Quality Collection Plans

• Hierarchy of quality collection data
• Parent Plan acts as a header record
• Parent and Child records are linked
• Parent/Child - conditional triggers that maybe
  used
• Non Conformance Flow Template
• Corrective Action Template

11
Templates For Non Conformance and Corrective
Action

• Predefined flow for Non Conformance
• Non Conformance multi-level
• Non Conformance light
• Predefined flow for Corrective Action
• Trigger off of Non Conformance
• Use as a standalone CAR system
• See Implementation Guide B10988-01 on Meta-link

12
Flexibility Future Changeability

• Quality systems require improvement
• Basic systems change
• Requirements and benchmarks more stringent
• Most of what you do today will be obsolete
  tomorrow
• Successful systems designed for growth
• Better processes less waste
• Competition drives cost and quality improvements
• Customer satisfaction is the ultimate QA test

13
Workflow, Approvals and Security

• Use Oracle Workflow to guide the process
• Approvals and Security are Available as Tools
• Alerts can be sent
• E-Mail notification is one powerful easy to use
  tool

14
Quality Integration in Manufacturing Execution

• Desktop forms
• Discrete Workstation
• Mobile Supply Chain Applications
• Work Orderless Transactions
• Serialization in WIP

15
Discrete Workstation Highlights

• Joins job information and transaction entry
• Dispatch list
• Support for quality data collection, lot/serial
• Component and resource requirements
• Component shortage view
• Work instructions (modeled as attachments)

16
Discrete Workstation
View work instructions
Component shortages for this operation

• Simplified transaction entry lot/serial, quality

17
Reporting Moves and Completions

• Move and complete assemblies
• Collect quality data
• Backflush lot and serial components
• Modify component quantity, revision, supply
  subinventory
• Assign serials or lots to assemblies at completion

18
Mobile Transactions

• Barcode scanning / Telnet based
• Component issue and return
• Resource consumption
• Assembly move, scrap, and completion
• Work orderless scrap and completion
• Quality collection triggered by transaction
• Standalone collection of quality data

19
Work Orderless Transactions

• Completions / Returns
• Scrap / Return
• Pros and Cons
• All components are backflushed
• Generally not appropriate for long lead time
  assembly
• Support for lot/serial entry and component
  substitution
• Quality data collection
• Quick and easy for high volume operations

20
Serialized Transactions

• For tracking serialized assemblies within a job
• Supported in Mobile only
• Association of predefined serial numbers to jobs
• Choice of serial birthing point
• All transactions begin with assembly serial number

21
Electronic Signatures

• Available in 11i10
• A means of capturing and storing an online record
  confirming that work was performed as documented
• 55 critical business events are enabled
• Designed based on device history requirements of
  medical device manufacturers per FDAs 21 CFR
  Part 11
• An added layer of security to the quality process

22
Genealogy Creation

• Serial and lot tracking and end-to-end genealogy
• Lot genealogy and serial genealogy are separate
  in Release 11i10
• Expecting enhancements, possibly visibility to
  quality data

23
Lot/Serial Tracking GenealogyVisibility to
Change History
Service/Repair As-Installed / As-Maintained
Discrete Manufacturing As-Built
End Assembly
End Assembly
Modified SubAssy
New SubAssy
SubAssy
SubAssy
New Component
New Serial
Lot Component
Serial Component
Component
Component
Component

• Trace Installation / Removal History
• Track Unit Specific Information
• Material Transactions Update Genealogy

• Multi-Level Product Structures
• Construct Genealogy

24
Other Strong Discrete Manufacturing Processes

• Job and operation scheduling
• Resource and Job Workbenches
• Flexible, automatic job creation
• Component picking
• Electronic signatures
• Integration with Warehouse Management

25
Job Operation Scheduling

• Available in Release 11i10
• Schedule fine-tuning
• Resource loading analysis
• Two GANTT charts one by resource, one by job
• Configurable to display only what you want to see

26
Resource Workbench
Load summary vs. capacity for selected resources

• View work queues and resource loads

27
Flexible Automatic Job Creation

• from Planning
• Create new jobs and reschedule operations
• Primaries or alternates based on your planning
  algorithm
• from ATO/CTO
• Multi-level creation now available
• Direct creation or through Advanced Planning
• from Production Kanban
• through Mass Load from an outside source

28
Component Picking

• More flexible than the Picking Report
• Choice of pick criteria date range, job,
  operation
• Rules-based picking ? system recommends supply
  locations
• Pick sets
• Pick slip grouping rules

29
Component Picking (cont)

• Pickers confirm quantity and location
• Enhanced with MSCA or Warehouse Management
• Confirmation performed on RF device
• Expanded task grouping and sequencing
• Run when needed or as a scheduled concurrent
  request

30
Integration with Warehouse Management

• Do You Need?
• Container management / license plating
• Warehouse task management
• Material status
• Discrete job picking and transactions fully
  support this integration
• Picked component ?Move order line ? Task
• Mobile assembly and work orderless completions
  into an LPN system recommended or user directed
  putaway

31
Summary

• WIP and Quality are tightly integrated
• Quality data collection is available through
  multiple types of transaction entry screens
• Quality plans can be used to capture information
  not enterable anywhere else
• Quality and WIP have robust support for numerous
  critical manufacturing business processes

32
Conclusion

• Questions on what was presented?
• Anything your not clear on?
• Open Discussion is encouraged.
• Comments on Oracle WIP or Quality?
• Thank you for your time and attendance.
• Come back for the next training day!!!

33
TRAINING DAY August 11,2006 Larry Gray
lgray_at_darc.com