Oracle Shop Floor Management improves manufacturing by offering real-time visibility and control and leveraging AI and IoT capabilities to integrate with other Oracle tools.
This article will discuss key features, such as real-time execution, detailed scheduling, and advanced lot management, and how our senior-level Oracle consultants can help you maximize your investment.
Key Takeaways
- Oracle Shop Floor Management integrates with Oracle Order Management for improved production efficiency. It leverages AI and Oracle Fusion Cloud to streamline complex lot transactions, routing, genealogy tracking, and operation yield cost modeling.
- Real-time execution is a key feature, with tools like the Supervisor Workbench enabling detailed job monitoring and control, tailored workstations for specific operational needs, and comprehensive tracking capabilities to ensure efficiency and informed decision-making.
- Advanced capabilities, such as flexible network routing, multi-level bills of material, component usage management, operation yields, and detailed scheduling and planning, provide manufacturers with robust tools for optimizing manufacturing tasks and resource usage.
Overview of Oracle Shop Floor Management
Oracle Shop Floor Management is an innovative solution that expands the capabilities of Oracle’s Manufacturing Applications by managing complex shop floor information and bridging the gap between Oracle Manufacturing and the shop floor. This system enables comprehensive, real-time management of shop floor activities, providing manufacturers with the tools to maintain visibility and control over their operations.
Oracle Shop Floor Management, integrated with Oracle Order Management, is distinguished by its ability to manage complex lot transactions, dynamic routing, end-to-end genealogy tracking, and operation yield cost modeling. This way, manufacturers can initiate and implement discrete and lot-based jobs within the same organization, bolstering flexibility and efficiency in their production processes. Additionally, the solution uses a single data repository to ensure information consistency for manufacturing execution, which is crucial for maintaining accuracy and reliability in production.
The system also leverages AI and adaptive intelligence through Oracle Fusion Cloud Manufacturing, streamlining mixed-mode manufacturing and enhancing production efficiencies. By integrating these advanced technologies, Oracle Shop Floor Management improves operational efficiency and helps manufacturers stay competitive in a rapidly evolving industry.
Real-Time Shop Floor Execution
Effective shop floor management relies heavily on real-time execution. With this consideration, Oracle Shop Floor Management offers a superior interface for monitoring jobs assigned to specific work centers. This interface supports job tracking capabilities, allowing supervisors to monitor each job’s progress and make informed decisions based on real-time data.
One of the key features of this interface is the ability to:
- Configure workstations for display, security, and transactions
- Tailor each workstation to the specific needs of the operation, enhancing efficiency and security
- Provide operators with necessary instructions and job requirements, ensuring they have all the information they need to perform their tasks effectively.
The Supervisor Workbench is another powerful tool within Oracle Shop Floor Management. It allows supervisors to split jobs, move jobs, and monitor job status, providing a comprehensive overview of shop floor activities. This level of control and visibility is crucial for maintaining efficient and effective production processes.
Detailed Scheduling and Planning
To optimize production efficiency, detailed scheduling and planning are vital. Oracle Shop Floor Management brings robust tools for real-time, department-level scheduling, guaranteeing precise planning and execution of each job. The system offers the following features:
- Real-time scheduling
- Department-level scheduling
- Calculation of the portion of jobs completed before the plan start date
- Scheduling for only the unfinished portion of jobs
- Streamlining of the scheduling process
Sequence-dependent setups are a key feature of the scheduling tool. By grouping activities of the same setup type, the tool minimizes changeovers, reducing downtime and enhancing overall production efficiency by avoiding repetitive schedules. Additionally, enhanced Gantt chart and planner’s workbench features provide a detailed view of information for critical planning activities, allowing for better decision-making and streamlined resource allocation.
Another valuable tool is the resource-centric workbench, which enables drag-and-drop job management, changing job priorities, and adjusting material/resource requirements. This flexibility is particularly beneficial for managing high-priority test lots, especially in the semiconductor industry, where precision and efficiency are critical.
Advanced Lot Management Capabilities
Oracle Shop Floor Management features advanced lot management capabilities indispensable for managing intricate manufacturing requirements. These capabilities include functionalities for splitting and merging lots, where split lots can have different resources, material requirements, and operations. This flexibility ensures manufacturers can efficiently manage their production processes, regardless of the complexity of their lot-based jobs.
Lot Transactions
Effective shop floor management hinges on proficient lot transaction management. Oracle Shop Floor Management accommodates various lot transactions, such as:
- Moves
- Splits
- Merges
- Renaming
- Transfers
These transactions, known as WIP lot transactions, allow manufacturers to perform operations like moving, scrapping, jumping, and undoing on a lot during lot-based manufacturing production.
Lot move transactions, in particular, are crucial for maintaining the production flow. They enable the move transaction of an assembly within an operation or to the next operation, with the option to include scrap transactions. This flexibility ensures production processes adapt to changing requirements and maintain efficiency throughout the manufacturing cycle.
Lot Genealogy
Oracle Shop Floor Management’s essential feature, Lot Genealogy, facilitates accurate tracking of historical production data and lot changes. This feature offers an inclusive tracking capability that includes defects and lot changes, delivering a detailed history of each lot’s progression through production.
These genealogy enhancements enable users to trace defects and track changes that lots might have undergone, facilitating better production management and quality control. Manufacturers can ensure accuracy and reliability in their production processes by maintaining a comprehensive history of lot information and related transactions.
Capturing Attributes During Lot-Based Jobs Execution
For precise tracking and inventory management, it’s vital to capture attributes during lot-based job execution. Oracle Shop Floor Management allows manufacturers to:
- Enter or update attributes specific to warehouse and inventory needs during job execution
- Update or view attributes at any stage
- Ensure inventory specifics are tracked and managed throughout the production process
Upon job completion, capturing attributes are transferred to the resulting inventory lot, ensuring data continuity. This seamless integration of lot attributes tracking into the job execution process enhances overall inventory management and accuracy.
Flexible Network Routing
Oracle Shop Floor Management’s robust and flexible network routing facilitates the dynamic definition of operation paths depending on the outcomes of previous operations. This flexibility allows for the definition of all possible operation paths that a job can take, ensuring production processes can adapt to changing requirements.
A routing network comprises a series of nodes and paths, providing a flexible structure for defining job operations. This network can define multiple potential operational paths, allowing jobs to follow different paths as determined during execution. This flexibility enhances the efficiency and adaptability of manufacturing processes, ensuring production can continue even when unexpected changes occur.
Multi-Level Bills of Material
With its capability to manage multi-level bills of material, Oracle Shop Floor Management caters to complex manufacturing requirements. This capability is essential for managing the various components and materials required for complex manufacturing processes. The system supports multiple supply types for lot-based jobs, including operation pull, push, and phantom.
Phantom assemblies are specifically utilized to:
- Group materials based on pre-defined criteria and process requirements
- Behave differently between discrete and lot-based jobs, ensuring material requirements are exploded during job creation and subsequent operations
- Provide flexibility in managing multi-level bills of material to ensure efficient handling of complex production processes
Component Usage Management
Manufacturers can define components with Basis as lots and issue a fixed quantity regardless of job quantity, enabling precise component usage management and ensuring manufacturing accuracy. This flexibility ensures component usage can be accurately managed, regardless of the complexity of the job.
Inverse Component Usage
Capturing inverse component usage is critical in accurately determining the total required quantity of a component for a job. This feature helps prevent variances in component usage by ensuring the required quantity is precise. The inverse usage value is accessible in multiple windows, such as the Lot Creation window, Lot Based Job window, and WIP Material Requirements window. This allows for flexibility in viewing and utilizing the data.
This precise tracking of component usage ensures manufacturers maintain accurate records and avoid discrepancies in their production processes. Oracle Shop Floor Management helps manufacturers optimize their resource usage and maintain efficient production processes by providing detailed information on component requirements.
Fixed Component Usage
Another key feature of Oracle Shop Floor Management is fixed component usage. It allows manufacturers to:
- Define a fixed usage quantity for components on a bill of material
- Ensure the total amount required remains unchanged, regardless of the build quantity
- Manage components that are required in fixed quantities for each job
The Bills of Material window allows users to select the basis type (item or lot) to calculate material requirements, providing flexibility in managing component usage. By supporting fixed component usage, Oracle Shop Floor Management ensures manufacturers can maintain accurate records of component requirements and avoid discrepancies in their production processes.
Component Shrinkage
Effective component shrinkage management is fundamental in maintaining precise records of component usage, including predicted and actual use. Oracle Shop Floor Management allows manufacturers to:
- Maintain the Quantity Per Assembly independently from the Component Yield Factor
- Prevent incorrect inflation of backflush quantities
- Account for yield when deriving the backflush quantity for component materials
The Component Yield check box in the WIP parameters enables the system to consider yield while deriving backflush quantity, ensuring accurate records of component usage. This functionality is crucial for maintaining accurate records and optimizing resource usage in manufacturing processes.
Operation Yields and Costing
Oracle’s operation yield costing features facilitate precise costing and production management. The system allows for the definition of operation-level yields on the routing of a product, facilitating accurate costing and management. The cost rollup considers material, overhead, and resource costs using the reverse cumulative yield, ensuring comprehensive cost tracking.
Actual yields for a lot can be tracked at all required operations, providing detailed information on production efficiency. This tracking helps identify variances between estimated scrap absorption and actual scrap, highlighting areas for improvement in the manufacturing process. Oracle Shop Floor Management helps manufacturers optimize their production processes and maintain accurate cost records by providing detailed information on operation yields.
Estimated scrap accounting is another valuable feature, enabling manufacturers to:
- Track the difference between estimated and actual scrap by operation and department
- Identify deviations from the standard BOM or Routing, providing valuable insights into departmental performance
- Maintain accurate cost records and optimize their production processes
By supporting operation yield costing, Oracle Shop Floor Management ensures manufacturers can maintain accurate cost records and optimize production processes.
Integration with Oracle Applications
A significant strength of Oracle Shop Floor Management is its integration with other Oracle applications. The system facilitates MES integration at the lot transaction level, ensuring seamless data flow between applications. This integration expands the capabilities of Oracle Shop Floor Management, making integrated shop floor information available at the enterprise level.
Oracle Shop Floor Management integrates with Oracle Advanced Planning for detailed scheduling functionalities, ensuring optimized production processes. Additionally, the system integrates with Oracle Planning to handle transactions, such as implementing planned orders as lot-based jobs. This seamless integration enhances manufacturing efficiency and customer responsiveness, ensuring manufacturers can meet the demands of a rapidly evolving market.
Oracle Cloud Manufacturing further enhances integration capabilities by connecting shop floor data with maintenance and planning systems through IoT. This integration improves product quality and reduces costs by streamlining the extended supply chain. By supporting comprehensive integration with other Oracle applications, Oracle Shop Floor Management ensures manufacturers can optimize their production processes and maintain a competitive edge.
Co-Products and By-Products
For process manufacturing, where multiple end items are produced from the same primary component, Oracle Shop Floor Management supports the definition of co-products and by-products. This functionality allows manufacturers to:
- Define an item as the primary component of several end items
- Facilitate the automated creation of bills of material for these end items
- Simplify the management of complex production processes
- Ensure that all necessary components are accounted for
The Define Co-Products window allows users to specify the expected distribution across all end items produced from a primary component, ensuring accurate planning and resource allocation. The system also supports the entry of split percentage values for co-products, which can be updated or adjusted over different periods. This flexibility ensures manufacturers can efficiently manage multiple end-item production and optimize resource usage.
Component Picking and Inventory Management
Maintaining smooth production processes requires efficient component picking and inventory management. Oracle Shop Floor Management offers the following capabilities to facilitate directed picking and put away:
- Allocate and place materials in optimal locations with Oracle Warehouse Management rules engine
- Streamlining inventory management operations
- Ensuring materials are readily available when needed
The rules engine can be customized to meet customer-specific requirements, including:
- Stock condition and quality
- Tasks relevant to operator skill sets
- Equipment requirements
- Equipment capacity
This level of customization and precision in inventory management helps manufacturers maintain efficient production processes and reduce downtime.
Oracle Warehouse Management also supports strict pick unit of measure (UOM) allocation to ensure standard pack sizes are not broken during picking. This feature, along with directed picking methods like FIFO (First In, First Out) and FEFO (First Expired, First Out), ensures proper stock rotation and minimizes waste.
By supporting comprehensive component picking and inventory management, Oracle Shop Floor Management helps manufacturers optimize their resource usage and maintain efficient production processes.
Tracking Completions with License Plate Numbers
Oracle Shop Floor Management facilitates the tracking of assembly completions with unique license plate numbers (LPNs). LPNs are used to track completions with unique identifiers for the contents of containers, ensuring accurate inventory tracking. This capability allows manufacturers to maintain detailed records of completed assemblies and their associated components, enhancing overall inventory management.
LPNs can represent a collection of items and do not necessarily need to correspond to a physical container. They can be generated using a concurrent request or directly on mobile devices during transactions, providing flexibility in their use. Once emptied, LPNs can be reused, with their status updated to ‘Defined But Not Used.’ This efficient tracking method ensures manufacturers can maintain accurate inventory records and optimize production processes.
Enhancing Manufacturing Efficiency
By granting real-time visibility and control over shop floor activities and processes, Oracle Shop Floor Management offers the following benefits:
- Boosts manufacturing efficiency
- Provides real-time execution
- Offers detailed scheduling and planning
- Allows for flexible network routing
- Helps optimize production processes
- Reduces downtime
By integrating with other Oracle applications and leveraging advanced technologies like AI and IoT, Oracle Shop Floor Management helps manufacturers improve product quality, reduce costs, and enhance overall operational efficiency. This comprehensive approach to shop floor management ensures manufacturers can stay competitive in a rapidly evolving industry and meet the demands of their customers.
Partnering with the Experts
Whether you need help implementing new Oracle applications, additional support navigating integrations between Oracle and non-Oracle systems, or just an extra hand streamlining communication across project teams, Surety Systems is here to help.
Our senior-level Oracle consultants have the knowledge, skills, and experience to understand your critical project needs and prepare your internal teams for long-term success.
Contact Us
For more information about our Oracle consulting services or to get started on a project with our team of expert consultants, contact us today.
Frequently Asked Questions
What is Oracle Shop Floor Management, and how does it benefit manufacturers?
Oracle Shop Floor Management benefits manufacturers by enhancing visibility, control, and efficiency in production processes through real-time management of activities, complex lot transactions, and effective operation yield costing.
How does Oracle Shop Floor Management handle lot transactions?
Oracle Shop Floor Management handles lot transactions through various supported operations such as moves, splits, merges, renaming, and transfers, enabling manufacturers to manage and track lot activities during production.
What is the purpose of flexible network routing in Oracle Shop Floor Management?
Flexible network routing in Oracle Shop Floor Management allows for a dynamic definition of operation paths based on the outcomes of previous operations, ensuring production processes can adapt to changing requirements and maintain efficiency.
How does Oracle Shop Floor Management integrate with other Oracle applications?
Oracle Shop Floor Management integrates with various Oracle applications, such as Oracle Advanced Planning and Oracle Planning, to boost manufacturing efficiency and customer responsiveness. Additionally, it connects shop floor data with maintenance and planning systems through IoT.
What are the benefits of using License Plate Numbers (LPNs) in Oracle Shop Floor Management?
Using License Plate Numbers (LPNs) in Oracle Shop Floor Management offers benefits such as accurate inventory tracking through unique identifiers for container contents, easy generation through concurrent requests or mobile devices, and the ability to reuse them once emptied.
