Flow Manufacturing
Valerie Dubois - Flow Mfg Product Strategy Steve Morgan - Flow Mfg Product Manager
Purpose: This document provides an overview of features and enhancements included in Release 12. It is intended solely to help you assess the business benefits of upgrading to Release 12. Disclaimer: This document in any form, software or printed matter, contains proprietary information that is the exclusive property of Oracle. Your access to and use of this confidential material is subject to the terms and conditions of your Oracle Software License and Service Agreement, which has been executed and with which you agree to comply. This document and information contained herein may not be disclosed, copied, reproduced or distributed to anyone outside Oracle without prior written consent of Oracle. This document is not part of your license agreement nor can it be incorporated into any contractual agreement with Oracle or its subsidiaries or affiliates. This document is for informational purposes only and is intended solely to assist you in planning for the implementation and upgrade of the product features described. It is not a commitment to deliver any material, code, or functionality, and should not be relied upon in making purchasing decisions. The development, release, and timing of any features or functionality described in this document remains at the sole discretion of Oracle. Due to the nature of the product architecture, it may not be possible to safely include all features described in this document without risking significant destabilization of the code.
Lean Primer
Planning
Mixed Mode Mfg Execution Repetitive, Flow / ETO Project Lean ATO / CTO MTS Standard WIP Lot-Based
Sample Analyze Adjust
Warehousing / Transportation
Suppliers
Quality Management
Asset Maintenance
Service
Production Status Material Availability Mfg Capacity Schedules / Changes Ship Notices Invoices / Payments
Partner Collaboration
Customer Enterprise Shop Floor Contract Mfgrs Suppliers
Framework to document flow mfg processes Simulates and calculates flow line design Designs material replenishment processes Sequences demand directly to production line Simulates daily demand for resource planning Provides line performance metrics
Benefits:
Lean processes that are sustainable and repeatable on a global scale 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 chain mgmt
Relentless talk of eliminating waste, or Muda Aversion to lots of WIP moves, queues, etc Customer asks about TAKT time, Kanban, Value Stream Mapping,
Linearity, Balanced Production
Customer talks about synchronizing supply, or Just in Time (JIT) supply You meet or hear about a Sensei, Lean Evangelist or Lean
Champion
Lean Planning
Lean Execution
Define and associate standard processes with product families, items, or configurable models. Add alternate paths & rework loops Add standard events Identify TQC and value-add events Associate work instructions Calculate line & operation takt, and reqd resources; highlight imbalances Eliminate non value-added work, regroup events into balanced operations, add IPKs, add resources Review TQC events for mistake proofing. Create quality collection plans
Standard Machine and Labor Calculations Cell Design and Operator Balancing Mistake Proofing
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Lean Planning
Flexible Component Replenishment Supports a Wide Range of Business Needs Full Support for Configured Products Kanban Execution Cards generated and printed Single and dual card kanban. One time kanbans Internal, production, supplier and inter-plant kanbans Out of the box integration with Mobile Supply Chain Apps Single step replenishment process Uses standard PO business logic to source material and communicate to supplier through iSupplier portal, fax, edi, XML or print Status of supply visible on the card, and history is tracked throughout the life of the card Synchronized Components Synchronize component pull by generating supplier and feederline kanbans based on the final assembly sequence Generate feeder line schedules directly from the parent line assembly sequence Generate a pick plan for low usage or large parts to pick components based on flow schedule sequence. Integrated with WMS
Lean Execution
Pick Components
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Advanced Sequencing and Simplified Execution Full Support for Configured Products
Production Sequencing Sequence sales orders or planned orders using simple level loading sequence rules Or create constraint based sequencing rules on any item, order, or component attribute Re-sequence flow schedules created by kanban pull or feeder line synchronization for a more optimal mix
Lean Execution
Enables a paperless factory Simplified user interface presents all pertinent information and transactions to the shop floor worker Dynamic work instructions that change as configurations vary In R12, assembly and component serial and lot numbers can be assigned at any operation and use that information during work orderless completion
Dashboards provide performance to schedule, inventory reports, on time delivery and quality metrics Linearity report and performance to schedule available within the flow application
Reporting
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Key Differentiators
Full Support for Configured Products Best of Breed Value Steam Analysis Functionality that Drives Manufacturing Flexibility and Efficiency
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Flow is harder to implement then WIP, so customers should defer it until after go live
But also sometimes TRUE - If a customer has not yet physically adopted
the lean principles on the shop floor, then it may be wise to implement a discrete process first, so they are adopting one new process at once
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Flow Manufacturing
Functional Deep Dive
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Ability to define set up at three levels Organization , Org / Line and Org /Line / Operation Options available are different depending on level selected.
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View all schedules provides ability to view all uncompleted schedules on all operations. Backflush option determines whether all components are backflushed or only the components on the primary routing.
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Action selection is fully configurable within the workstation setup. User can determine which actions are buttons are which actions appear in the drop down list. Page Regions , Tab Regions , Instructions and Actions are all fully configurable. Express Complete Schedule allows fast schedule completion with minimal user input.
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Additional actions available are Scrap Assembly and Express Complete Schedule. Actions appear as buttons or in the action drop down list based on setup preferences.
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Select the Update Schedule action to review or modify the Flow Schedule header information
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. Can update Flow schedule details at any time including entering lot and serial information. Calls Inventory functions to generate lot or serial numbers.
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. Ability to record component usage , add or delete components and record component lot or serial information at each operations Ability to associate component serials to parent serials for serial genealogy tracking.
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. Allows multiple lot and serial numbers to be entered for the Item.
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. Assembly scrap information can be entered on this page including scrap amount, scrap reason and lot/ serial information.
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. Express completions will attempt to complete the Flow schedule with all of the default settings. Normal completions allows for review and update of the Flow schedule header information including lot and serials. Any information changed/added at prior operations will be defaulted here.
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. If component usage or lot / serial information has been recorded at a prior operation , then the list of backflush components will reflect these changes. For each component that is lot or serial controlled, can drill down and enter multiple lot / serial numbers and link those to parent lot / serial numbers for lot / serial genealogy.
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. In line quality collection can be done from the Line operation completion or Flow schedule completion transactions. If the quality plan is mandatory, then quality information must be entered before completion can be finalized.
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Oracle Quality
Oracle quality provides the framework that allows viewing and entering the quality data related to flow operation completion and flow schedule completion transactions. This module is integrated with flow execution workstation to allow seam less collection of data.
Oracle Inventory
Allows recording of lot and serial numbers for assembly and components. This module is integrated to allow data recording while doing the work order less completion transaction.
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Benefits
Extends the concept of the paperless shop floor by allowing the operator to record actual production information as it happens Improves performance and efficiency by directly embedding the completions and quality collection transactions into the flow execution workstation so that all transactions can be executed within the workstation.
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Feeder Line synchronization Outbound Broadcast Sequencing Kanban Planning Flow Execution workstation Flow Sequencing
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Benefits
Supports fixed component usage which allows the component quantity to remain fixed regardless of the parent assembly quantity.
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When the flow schedule is rolled forward, the new schedule will now be created with the original schedule ID to ensure that any existing documentation is still valid.
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Benefits : Ensures that any pre-printed documentation is still valid with the rolled flow schedule.
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White papers available in class to provide more detail around transitioning to Lean and how Oracles Flow Mfg capabilities can enable this transition.
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Flow Manufacturing
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FLM: Enable Flow Sequencing This profile option is added to determine whether flow sequencing is purchased and thus enabled.
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Thank You
Thank You