Oracle Apps Manufacturing & Distribution

Author
Jagan Vidyala

Freelance Consultant and Corporate Trainer
ORACLE SCM / MFG / ASCP / EAM Suites

10 Yrs of experience in IT consulting in
addition to 18 Yrs of domain experience in
Manufacturing, Inventory, Global
Procurement, Sales & Marketing and
Turnkey Project execution.

jvidyala@gmail.com +91-91774-77013

Overview
Warehouse Management
Processes of a Warehouse
Processes of Warehouse
Receiving: Receiving material and
finished goods.
Put away: Put away materials and
finished goods you receive.
Storage: Storage items within the
Warehouse.
Picking: Pick orders for manufacturing
and shipping.
Packing: Pack orders for shipping.
Shipping: Ship orders to customers.
Value added services: Manufacturing,
assembly, knitting, and labeling.
Warehouse Management

Supply Chain Inventory Management

Inbound
Logistics
Storage
and Facility
Mgt.
Mfg and
Value
added
Services
Outbound
Logistics
Reverse
Logistics
Supply Chain Inventory Mgmt
Components
Inbound Logistics: Includes receiving
directly into inventory, receipt inspections,
label printing, and rules-based directed put
away to storage or opportunistic cross
docking
Value Added Services: Includes labeling,
packing, and kitting
Outbound Logistics: Includes picking,
staging, packing, product consolidation,
loading, and shipping
Reverse Logistics: Includes product
returns, refurbishment, and recycling
Supply Chain Inventory Mgmt
Components

Storage and Facility Mgmt: In addition to
Oracle's suite of Mixed Mode
Manufacturing storage and facility mgmt
module, Warehouse Mgmt extends intra-
organization replenishments, container
mgmt, storage space optimization, cycle
counting and physical inventory, and
physical warehouse mapping.

Additional Product Requirement
To use Warehouse Management, you must implement INV, PO,
BOM, and OM.

Inventory to setup items, Orgs, SI and Locators.
BOM to define resources people, and calendars.
OM and PO provide the basic shipping and receiving
capability on which Warehouse Management builds.
Warehouse Management Application Hierarchy
Warehouse Management















LPNs
Task
Mgt.
Material
Mgt.
Lot, Split
Merge
Rules
Engine
Mobile Supply Chain Applications





















Oracle Mobile (RF) Technology
Existing: Oracle Manufacturing & Distribution Applications






BOM
WIP
Quality
Project
Mfg.
Inventory
Order Mgt.
Shipping
Purchasing
Receiving
Mobile Supply Chain Application
MSCA provides a mobile user interface for
existing inventory, receiving, manufacturing,
quality, and shipping transactions.
The mobile environment provides operators
with an alternate set of pages to perform the
transactions supported in these
environments.
Operators can use hand-held frequency
devices to perform transactions in both WHM
and MSCA.
WHM extends the capability available in
MSCA to encompass the demand placed on a
dynamic high-volume warehouse.
WHM - Features
WHM provides the following features in
addition to features provided in MSCA
Task management
Material tracking with LPNs
A configurable rules engine that enables
to create custom picking rules, put away
rules, and compliance labeling rules.
Advance inventory and material mgmt
including material status, lot, and serial
support.
WHM also is heavily integrated with, and
extends some of the current functionality
in manufacturing applications.
Inbound Logistics - Tasks
Receiving with or without ASNs

Receipt check-in

Quality control inspection

Bar code printing

Directed put-away and storage optimization

Opportunistic cross docking
Inventory, Storage, and
Facility Mgmt - Tasks
Container and license plate management
Subinventory configuration
Advanced locator definition
Kanban replenishment management
Move orders (intra-org transfers and issues)
LPN based WIP completions
Task dispatching
Material status control
Lot and serial genealogy and tracking
Visibility of inventory ownership
Cycle counting and physical inventory
Date coding and shelf life monitoring
ABC classification and analysis
Value Added Services - Tasks
Kitting and dekitting

Customer compliance labeling

Mixed-mode manufacturing
Outbound Logistics - Tasks
Wave picking
Pick methodologies
Dock assignments
Directed picking rules
Task dispatching and interleaving
Task monitoring through the Oracle
Warehouse Management Control Board
Cartonization and packing
Interface with compliance labeling system
Shipment stage, consolidation, and loading
Shipment verification and close
Reverse Logistics - Tasks
Return Material Authorization (RMA)
receiving

Return To Vendor (RTV)

Refurbishment and Recycling

Optionally, if Oracle Service and Oracle
Depot Repair, then use Warehouse Mgmt
as part of the refurbishment or recycling
process.
Inventory, WHM and MSCA
Capability Inventory Warehouse
Management
MSCA
LPN Management No Yes No
Task Management No Yes No
Counting Yes Yes Yes
Rules No Yes No
RFID No Yes Yes
Label Printing No Yes Yes
MSCA provides a streamlined radio frequency based interface for
core inventory, shipping, quality, WIP, and receiving capabilities.

Warehouse Mgmt extends these capabilities beyond the base
functionality Inventory and MSCA provide.
Inbound Logistics
Outbound Logistics
Outbound Logistics
WMS Control Board: Provides warehouse managers with
a real time snap shot of the warehouse, and enables
them to redistribute operators as needed. They can
monitor the progress of tasks as well as manually
dispatch tasks to operators.
Consolidation: WM enables operators to consolidate
partially filled containers into fewer and better-optimized
containers.
Dock Appointment for Trips: Managers can use
Warehouse Mgmt to schedule outbound carrier
appointments, dock door availability, and staging lane
usage within the warehouse.
Shipment Verification and close: Once operators pick and
load an order, the system automatically determines the
items and qualities to deduct from Inventory.
Value Added Services
Value Added Services
Kitting and De-kitting: Supports kit to stock(work
order-less completion)and kit to order Pick to order).
Mixed-Mode Manufacturing: Supports ATO, project-
based or ETO, discrete and repetitive or flow
manufacturing concurrently.
Manufacturing Component Picking: Supports picking
for WIP through the mobile user interface.
Manufacturing Assembly Completion and Put Away:
Supports WIP completion and put away through the
mobile user interface.
Manufacturing Quality Inspection: The statem
automatically generates material movement
transactions to move an item into the quality control
inspection area from manufacturing , based on
options defined during implementation.
Value Added Services

Product Compliance Labeling: Supports product
specific labels, based on rules defined.
Manufacturing Quality Inspection: The statement
automatically generates material movement
transactions to move an item into the quality control
inspection area from manufacturing , based on
options defined during implementation.
Integration with Project Manufacturing, Flow Mfg,and
Shop Floor Manufacturing: WM integrates with Project
Mgmt, Flow Mfg, and Floor Mgmt.
Integration with Project Manufacturing, Flow Mfg,and
Shop Floor Manufacturing: WM integrates with Project
Mgmt, Flow Mfg, and Floor Mgmt.

Storage and Facility Management
Mobile Application Architecture
License Plate Numbers (LPNs)
Nesting LPNs
LPN Context
Resides In Inventory
Resides in WIP
Resides in Receiving
Resides in In-transit
Issued out of Stores
Pre-generated
Packing
Picked
Defined but not Used
Resides at Vendor Site
Pre-pack for WIP
Loaded for Shipment
LPN Context
LPN Context
LPN Context
Material status
SI and Locator - Material status
Lot and Serial Attributes
Material Allocation
Allocation Decision Tree
Rules Setup
Define Rules


Define Strategies


Assign Strategies in Rules Workbench
Define Rules: Restriction
Define Rules: Sort Criteria
Define Rules: Default
Strategies
List of Rules


Different levels


Assign Strategies
Task Type, Label Format, and
Operation Plan Selection Rules
Are not assigned to strategies

Linked directly to an organization

Rule weight determines search order
Consistency Requirement
Rules Simulation
The rules Engine Simulator enables to
create and debug the picking and put
away processes.

Use the rules simulator for the following:

Test individual rules
Test strategies
Test the rules process
RFID Technology
Unique identifiers

Associate identifiers with system records

Export events to Warehouse Management

Report Exceptions


Radio Frequency Devices
WHM Supports, two types of UIs

1. Telnet - telnet over TCP/IP

2. GUI - J2ME compatible Java virtual
machines

Labeling
Label Types
Label Types
Label Formats
Assigning Label Types to Business Flows
Print labels automatically as part of the
business flow

Associate a label type to more than one
flow

Receiving Flows or Routings
Subinventory Types
Locator - Types
Document based Receiving
Item based Receiving
Receiving Methods
Standard Routing Flow
Inspection Routing Receipt
Direct Receipt Flow
Express Receipt Routing
Express Receipts
Mixed Receipt Routing
Desktop vs. Mobile Receiving
Receive Inspection Put away

Desktop

Desktop Desktop
Desktop

Mobile Mobile
Mobile

Desktop Mobile
Mobile

Mobile Mobile
Material is loose

Material Resides in LPN*

Material Resides in LPN

Material Resides in LPN
Mobile Receiving Option
Unavailable Mobile Receiving Option
LPN Receipts
Lot and Serial Receiving
Automated Matching of Received Material
Automated Matching of Received Material
Receiving - GTINs
GTIN - Setup
Quality vs. Purchasing Inspection
Standard Inspection
accepted material
Quality Inspection
accepted material
Inspection Storage Requirement
Returns
Responsibilities

Whse Mgmt Super User Vision Operations (USA)

Warehouse Manager

Whse Mgmt Mobile User Vision Operations (USA)

Whse Mgmt


Cost Groups
Cost Groups
System Assigned Cost Groups
System Assigned Cost Groups
Warehouse Mgmt assigns a cost group to inbound
material at receipt.
Set up rules to determine the appropriate cost
group based on item, item category, and supplier.
If the system does not find a appropriate cost
group it will assign default cost group of the SI
where the material is put away.

Cost groups are assigned by system when the
following transactions are performed
Material is put away in a storage locator
Material is cross docked
Any material movement in an operation plan
which is in inventory.

Cost Groups Setup
1.Define cost group for org
2.Define subinventory and
assign default cost group
3.Define cost group rules
4.Define cost group strategies
5.Assign strategies in rules
workbench
Commingling
The system prevents commingling of items when
cost group is the only distinguishing characteristic
between two quantities of loose inventory within a
single locator or LPN
Multiple cost groups of a single item may reside
within a single Locator or LPN as long as each cost
group is uniquely identifiable.
System Assigned Cost Groups
Warehouse Mgmt assigns a cost group to inbound
material at receipt.
Set up rules to determine the appropriate cost
group based on item, item category, and supplier.
If the system does not find a appropriate cost
group it will assign default cost group of the SI
where the material is put away.

Cost groups are assigned by system when the
following transactions are performed
Material is put away in a storage locator
Material is cross docked
Any material movement in an operation plan
which is in inventory.

Put Away Rules
Put Away Rules
Possible uses of Put away rules

Direct an operator to put away an item in the
same locator where other quantity of the item
already resides.
This minimizes item fragmentation.
Prohibit commingling of different items or
different lots of the same item in a single locator
Avoid lot commingling in a locator
Base the put away location on inspection results,
the type of purchase order, or item category
Direct operator to put away items based on
refrigeration restrictions
An operator can override suggestions of put away
rule, must provide reason code for override.
Restrictions and sort criteria for
Put Away Rules
Setting Up Put Away Rules
Define Rules
Define Strategies
Assign Strategies
1.
3.
2.
Setting up Put Away Rules: Define Rules
Setting up Put Away Rules: Define Strategy
Setting up Put Away Rules: Assign
Strategies to Business Objects
Put Away
Put Away Load
Put Away Drop
Put Away Drop
Put Away Drop Nested LPN
Item Based Put Away
Item Based Put Away
Cross Docking Put Away
Cross Docking to Outbound staging Flow
Advance Task Framework (ATF)
Advanced Task Framework

Model and Manage Complex Inbound Business
Processes

The Advanced Task Framework is:

Tailorable
User-definable
Balances Work load
Advance Task Framework
Advanced Framework enables to configure and
execute complex material flows for inbound items.
Plan and configure material flows to address specific
business objectives. It also simplifies the inbound
material movement execution process.

ATF enables to
Perform multi-step material movement
Define sequence of operations to be performed
during material flow
Define predictable material movement paths
Perform advanced operations such as
incremental consolidation, sorting, and packing
Use zones to balance workloads
Monitor progress
ATF Capabilities
ATF Capabilities
Use ATF to perform following functions:

Consolidation of similar items for palletization
Consolidation of items going to the same location
Deconsolidation of LPNs with mixed items
Movement of material requiring inspection to inspection
location
Movement of loose material to packing station
Use of Pick and Drop Locator to Perform an "n" step put
away
ATF Concepts
Activity: An activity can be defined as one or more
consecutive operations performed on material in a
warehouse in order to accomplish a specific
warehousing function. Example-Put away
Operation Plan: Planned sequence of operations.
Three types of operations are Standard, Inspection,
Cross dock
Load: Load is the act of picking material from a
locator and transferring it into the hands of an
operator, onto equipment, into a tote, or onto a
conveyor. An operator performs loads when material
needs to be moved. Loading is the first step performed
for material movement.
Drop: Drop is the act of dropping loaded material
into a locator. A load operation should always precede
a drop operation.
ATF Concepts
Task: A task is the unit of work a warehouse
performed by a warehouse worker, automated
equipment, or a work-equipment combination.
A task and a operation are two different things. A task
is the work performed on the warehouse floor, where
as operation is what defines the task to perform.
A task is an instance of an operation.
Material Grouping: use operation plans to control
material grouping in locators and LPNs during
intermediate moves. Consolidate material in a locator/
LPN based on Destination / Operation / Subinventory /
Similar item.
ATF Concepts
ATF Example
ATF Example
ATF applies to standard and inspection receipts. ATF
cannot be used for Direct routed receipts. Above
example is complex receiving process use ATF to map.

Material received into the R1.1.1 receiving SI is routed
to either to the inspection area, to inventory, or to an
outbound staging area.
Each operation shows how material moves through the
warehouse. The rules engine selects the operation
plan, the material is moved from operation to
operation until it is finally inspected, put away in
inventory, or cross-docked
ATF Setup
1.Zones (Optional)
2.Put away rules (Optional)
3.Put away strategies (Optional)
4.Strategies Assignment (Optional)
5.Defien operation plans
6.Define operational plan rules
ATF-Zones: Setup
ATF Operation Plan Setup
Warehousing Features
Describe Warehouse Mgmt vs. partner
label printing responsibility

Define printers

Know what to print

Describe task types

Describe resources

Explain the Warehouse Control Board
Compliance Labeling
Warehouse Mgmt vs. partner label
printing responsibilities
Label Printing Components
Setup
Register label formats
- Associate label formats to label types
- Specify list of used fields

Assign label types to business flows

Build labeling rules

Define printers

Assign printers to label types

Registering label Formats
Assigning label types to business flows
Label format Assignment Rules
Defining and Assigning Printers
Printing Mode
Profile Options:
WMS: Print Mode determines print mode
Asynchronous Mode
Synchronous Mode
Synchronous Mode TCP/IP
Viewing Label Requests