EDU42D9Y

Updating Material
Requirements
Overview
Copyright Oracle, 2008. All rights reserved.
Updating Material Requirements

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System References
Distribution
Job Title*
Ownership
The Job Title [list@YourCompany.com?Subject=267657635.doc] is responsible for ensuring that
this document is necessary and that it reflects actual practice.

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Objectives
Objectives
After completing this lesson, you will be able to:

Understand an overview of material requirements
Assign supply types to component requirements
View and update material requirements
Understand backflush transactions
Assign lot and serial controlled items
Use the component pick release program for
replenishment
Understand outside processing in replenishment

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Agenda
Agenda
Overview of Material Requirements

Component Supply Types
Viewing and Updating Material Requirements
Overview of Backflush Transactions
Assigning Lot and Serial Controlled Items
Using the Component Pick Release Program
Outside Processing in Replenishment
Summary
Instructor Note
Refer participants to the Oracle Work in Process Users Guide for detailed information
regarding material requirements.

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After a job is released, you build it by issuing components.

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When you define a job, the assembly bill created in Bill of

Materials is copied to the job:
Material requirements are copied from the BOM items
The BOM is exploded to create component requirements
Non-standard jobs can use bill of material references
Supply types control how components are delivered

For non-standard jobs, bill of material references are used to create material requirements, but
references are not required. You can define the job without material requirements, and then
customize by adding requirements.
Instructor Note
Refer participants to the Oracle Bills of Material Users Guide for detailed information
regarding defining job components.

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When you define jobs and schedules, you can control

material by:
Combining bills with routings to create requirements
Associating material with an operation on the routing
Specifying when and where materials are issued and
backflushed
A
Overview of Material Requirements (continued)

When you define jobs and schedules you can combine standard, alternate, or common bills of
material and routings to create specific material requirements anywhere in the routing. The
assembly revision determines which version of the bill of material is used to create the
requirements.
Note: You can create material requirements without routings. They are assigned to a default
operation sequence of 1.
Backflush transactions are material transactions that automatically issue component items into
work in process from inventory when you move or complete the assembly.

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Push and Pull Requirements

Component Pick Release Program
Material Transaction Processing
Load Requirements from External Systems
Pull
Push
Overview of Material Requirements (continued)

Push and Pull Requirements
You can push (issue) and pull (backflush) components items to jobs and schedules. A
component's supply type determines how it is supplied.
Component Picking
You can issue components using the Component Pick Release program. You can also use a
rules based system to determine a recommended source location for components.
Transaction Processing Options
Profile options are used to set material transaction processing such as online, concurrent, and
background processing.
Inventory Transaction Interface
Work in process material transaction information can be loaded from external systems such as bar code readers and other data collection devices - into the Inventory
Transaction Interface.

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Aligning ECOs for Work in Process and Planning

In Oracle Advanced Planning, the ECO Use-up Date is the date when the on-hand
quantity is calculated to be 0. It is calculated from inventory supply and requirement
demand. A profile option is provided, MSC:Release WIP Details if Order Date Different than
BOM Revision Date, to align work in process production with engineering change orders in
planning. This enables you to control resource and component schedules calculated by
planning, and forwarded to Work in Process when ECOs exist. Production order
recommendations from planning can either ignore active ECOs, or assume future ECOs are
already active.
Instructor Note
Refer participants to the Oracle Advanced Planning Implementation and Users Guide for
detailed information regarding Engineering Change Orders User-Up Effectivity.

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WIP Parameters - Material
WIP Parameters - Material
The Material tabbed region of WIP Parameters set

material transaction behavior:
Include Component Yield
Backflush default parameters:
Lot control parameters
WIP Material Parameters

Include Component Yield
Component yield is factored into component quantities during transactions. The quantity is an
entered value on the bill of material. You can disable this function to avoid inflating transaction
quantities during execution.
Backflush Default Parameters
Supply Subinventory and Supply Locator determine default values when backflushing
components if not defined on bill or inventory item level.
Release Backflush Components is used with the Component Pick Release program to
consider both pull and push components.
Lot Control Parameters
Lot Selection Method determines how lot controlled component items are selected during
backflush transactions.
Alternate Lot Selection Method is used for Selection Method set to Transaction History.
Lot Verification is used with selection method of Receipt or Expiration Date.

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Allow Quantity Changes During Backflush enables changes to the transaction to provide
the ability to over or under issue pull components when lot or serial entry is required..

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Component Yield and Shrinkage

Bill of Material
Item
Components
Yield
Inventory
Issue more
components
Work in Process
Return rejected
components

Component yield is the amount of a component you require to build, plus the amount of the
component you lose or waste while building an assembly:
The aggregate required quantity can be inflated to allow for shrinkage.
A yield factor of 100% indicates no loss in the manufacturing process.
A yield factor of less than 100% indicates that less than 100% of the components you
issue survive the build process and component usage quantity increases.
The cost rollup optionally includes the effect of component yield in the assembly costs.
The Include Component Yield parameter lets you disable this calculation.

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Simulating a Discrete Job
Simulating a Discrete Job
You can simulate a standard job to determine what materials

are required. In the Simulate Discrete Jobs window:
You can view on-hand and ATP quantities of components
Vary the quantity and dates
Save the simulation as a job
Refer to Practice Inventory Material Setup [LAB42E7Y]

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Agenda
Agenda

Summary

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Supply types control how to issue your components for
the job.
Based on bill
Equal to those on the bill of material
Assembly pull
Issued when you complete assemblies into inventory
Bulk
Not automatically transacted to the job
Operation pull
Issued when you complete the operation where the

components are consumed
Push
Issued using the Material Transaction window
Supplier
Vendor supplies components directly to Work in Process
Phantom
Components are issued for non-stocked assemblies that

group items

By synchronizing your bill of material with routings, you can specify when and where
materials are to be issued or backflushed to your jobs and schedules You can assign supply
types to the items you define in Oracle Inventory, or define them on the bill of material. Supply
types can also be changed when you create the job or schedule. If you change the supply type
on your work order, you are overriding the supply types for all the components on that job. You
can update the supply types of individual material requirements using the Material
Requirements window.
Based on Bill
This supply type uses the bill of material information. If there is no bill or routing for the job,
the system automatically changes the supply type to Assembly Pull.
Assembly Pull
Components are issued when assemblies are completed. They are pulled from the supply
subinventory assigned to the component requirement. You cannot assign this supply type to a
non-standard discrete job if you have not specified an assembly or bill of material reference.

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Floor stock
Bulk
Supplier
Outside Processing
Miscellaneous
issue
Push
Complete
Subinventory
Finished Goods
Operation pull
backflush
Replenish
Assembly pull
backflush
Floor stock
Component Supply Types (continued)

Bulk
Bulk components are used on the shop floor, but are not transacted. Bulk components are not
backflushed, you manually issue specific bulk components to a job.
Operation Pull
These components are issued to discrete jobs and schedules when you complete backflush
operations. Components are pulled from the supply subinventory assigned to the component.
They require a routing.
Push
Push components can be issued directly to jobs and schedules as required.
Supplier
These are the component materials that your suppliers provide, but you do not transact them.
Supplier components are not backflushed, nor do they default when issuing all components for
an assembly.

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Phantom Assemblies
Phantom Assemblies
Phantom assemblies are non-stocked items, grouping

material needed to produce an assembly.
Base Assembly
Plastic Base
Motherboard
Holder
Cable
Assembly
(phantom)
Wire
Standard
Screws
Plugs
Phantom Assemblies
Phantoms behave normally when they are top level assemblies, such as when master scheduled
or manufactured on a discrete job. As subassemblies, they lose their distinct identity and
become a collection of their components. Work in Process does not recognize the phantom
subassembly itself, and only sees and lists the individual phantom components on the bill of
material (although the phantom subassembly is recognized in Oracle Planning products).
You can specify that phantom subassemblies maintain their own operation sequence numbers,
and their resource and overhead costs are charged to the parent or higher level assembly, by
setting up two parameters in Oracle Bills of Material.

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Agenda
Agenda

Summary

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Requirements are viewed in a number of windows.

Material Requirements
Main
Qty
Component
MES Workstation
Components
Discrete Workstation
Status
Op Seq

You can view and update material and component requirements in a variety of ways:
On the Discrete Jobs window, choose Components. The Material Requirements window
appears when you access Components. You can then view detailed information about
components in the window's tabbed regions.
The View Material Requirements and Material Requirements window display material
requirements across jobs and schedules and for individual records.
On the Discrete Workstation, you can view component requirements on the Component
Requirements canvas for a particular job.
On the MES Workstation, you can access the Components section of the Work Content
and Job Details pages, and navigate to the Transact Components page.

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Job status determines the ability to update material.

Job Status
Add
Update Delete
Unreleased
Released
Only if requirements
have not been issued
On Hold
Complete

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Material Requirements and View Material Requirements Windows
Material Requirements and View Material

Requirements Windows
You can add material requirements to jobs and schedules
not required by the job.
Material Requirements
Job
Main
Component
Quantities
Op Seq
Supply
Repetitive
Department
Required

These windows enable you to view and update material requirements for individual jobs and
schedules, and also across jobs and schedules. When you a select components to update your
job, you have the following options:
Adding engineering items as requirements if the WIP:See Engineering Items profile
option is set to Yes.
Selecting Operation Sequence number to identify where material is required. You can only
add components at existing operations. For a job or schedule without a routing, the system
displays 1 as the default operation sequence.
Changing the Date Required field. The default for jobs and schedules with routings is the
start date of the operation. Without routings, the system displays the scheduled start date.
Changing the default Basis Type. This value comes from the bill of material and is used
for calculating component requirements. It has the following choices:
- Item: Usage quantity is the amount required per job and multiplied by the job
quantity.
- Lot: Usage quantity is taken directly from the bill of material and not multiplied
by job quantity. Component usage is fixed per lot.

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Material Requirements and View Material

Requirements Windows
View Material Requirements

Main
Component
Quantities
Op Seq
Supply
Repetitive
Department
Required
Material Requirements and View Material Requirements Windows (continued)

Changing the Required Quantity for the component. It is calculated based on basis type.
If you are adding a component, the per assembly quantity defaults to 1 and the
required quantity is derived from the job or schedule quantity and displayed in the
component's primary UOM. You can also enter a required or per assembly quantity of
zero.
Updating the Inverse Usage and Yield fields. They are used to enter values in cases where
decimal quantities may inflate requirements, or cause variances in rounding calculations.
Updating values in the Supply tabbed region. If the item does not have a supply type, the
value defaults to push. If the component's supply type is assembly pull or operation pull,
you must select the supply subinventory.

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Provides a graphical view of the shop floor, you can:

Perform shop floor activities by accessing WIP
transaction windows
View components for a job
Perform issue, return, or transfer transactions
On the Discrete Workstation you can view components in the Component Requirements panel
for all components used on a job.
In the Assembly Moves, Component Shortages, Time Charges, and Properties panels you can
choose Issue Components to access the Material Transactions window. From here you can
choose various transaction types such as issue, transfers, or returns.

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MES Workstation
MES Workstation
You can view and create component transactions
including:
Issuing and returning components
Entering subinventory, locator, lot, and serial data
Defaulting push components
MES Workstation
Components
Status
Op Seq
MES Workstation
The MES Workstation for the operator includes one tabbed region that provides Manufacturing
Execution System (MES) capabilities on top of Oracle Work in Process. It provides the ability
to view the work dispatch list, and then navigate to a number of transaction windows. You can
view and create component transactions from the Transact Components page, accessed from
the Dispatch List. This page enables you to create a number of component transactions
including:
Issuing and returning components
Entering subinventory and locator information
Entering applicable lot and serial number data
This page also has a feature for defaulting the display to supply type push components.

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Kanban Replenishment
ABC0024
Quantity
Supplier
Site
: 50 BX
: A-1 Lighting
: Sacramento
Kanban Location
Organization : SAC
Subinventory : Stores
Locator
: 1.1.1
Point of Use
Supplier
In a pull-based system, inventory items are replenished as soon as they are needed. Kanban
cards are used as replenishment signals. The term kanban refers to a visual replenishment
signal, such as a card or an empty container for material. In a kanban system, each workstation
can have several containers, each holding the same quantity of material. These cards generate
material requests automatically. Kanban material replenishment is a self-regulating pull system
to pull the minimum amount of material possible into production bins to meet demand. Kanban
replenishment enables you to:
Minimize inventory investment
Increase inventory turns
Stage material at point of use
Integrate suppliers into the supply chain
Eliminate work order kits
The source type of the kanban card determines how the material is replenished. A supplier
kanban may automatically trigger a purchase order to a supplier, while an internal kanban
results in an inter-organizational transfer.

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Demand
Container
Size
Kanban Card
BOM Explosion
Determines Average Daily

Demand
Kanban Replenishment (continued)

Kanban planning is used to calculate the kanban container quantity or number of containers,
for each item at each point of use. Demand is specified for the finished assemblies and their
bills of material are exploded to derive component quantities at consumption points.
Kanban cards, created in Oracle Inventory. In Oracle Flow Manufacturing, you can both plan
and execute kanban replenishment. The Graphical Kanban Workbench combines kanban setup,
kanban planning, and pull sequence definition in one interface.
Instructor Note
Refer participants to the Oracle Inventory Users Guide for detailed information regarding
kanban card setup. And refer participants to the Oracle Flow Manufacturing Users Guide for
detailed information on the Graphical Kanban Workbench, and replenishing kanban material in
the Flow Execution Workstation.

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Agenda
Agenda

Summary

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Material transactions that automatically issue

component items into work in process - when you
move or complete the assembly.
OP 10
OP 20
OP 30

Backflush transactions occur either during move or completion transactions. These transactions
pull components with operation pull and assembly pull supply types from inventory into jobs
and schedules. Backflush transactions can be launched by:
Completing assemblies at operations using the Move Transactions window
Moving and completing assemblies into inventory using the Move Transactions window
Completing assemblies into inventory using the Completion Transactions window
Receiving assemblies from an outside processing operation using the Oracle Purchasing,
Enter Receipts window
Move transactions imported through the Open Move Transaction Interface
Transactions imported through the Oracle Inventory Open Transactions Interface
Instructor Note
Refer participants to the Oracle Integration Repository at http://irep.oracle.com, for
information on the Open Move Transaction Interface and the Open Transactions Interface.

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Backflushing reduces the number of manual material

transactions required to process the jobs and
schedules
Overview of Backflush Transactions (continued)

You can reverse backflush transactions and automatically return backflushed components back
to inventory. For example, pull components that are backflushed as you move assemblies to the
next intraoperation step in a routingthey are automatically returned to inventory if you move
assemblies to a previous step in the routing.
Backflush transactions are enforced by the following rules:
A default supply subinventory must be defined for the component
Routing references are specified for non-standard jobs
Component item is transactable in the Inventory item master record
Backflush quantities in decimal values must be no more than five decimal places
Yield calculations are based on exact requirements, rather than rounded values
Assembly and operation pull components under lot, serial, or lot and serial number control can
be backflushed. The Backflush window provides efficient entry for large numbers of lot and
serial controlled items when creating assembly move transactionsincluding scrap, reject, and
assembly completion.

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Note: Push components that are requirements of work order-less schedules are always
backflushed.

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Agenda
Agenda

Summary

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Overview Lot and Serial Number Control
Overview Lot and Serial Number Control
SN0024
SN0025
SN0026
Lot 3
Lot 2
Lot 1
Overview of Lot and Serial Number Control

Oracle Work in Process supports serial number and lot number control for material
transactions. When performing issues, returns, and completions, you can enter serial numbers
or lot numbers, or both for items under control:
For serial control, when issuing items to work in process, you can use the predefined or
dynamically created serial numbers assigned upon receipt of an item into inventory.
For lot control, you can use the lot number assigned upon receipt of an item into inventory
when issuing that item to work in process.
You can perform serialized move transactions through Oracle Mobile Supply Chain
Applications using a mobile device.
Instructor Note
Refer participants to the Oracle Inventory Users Guide for information on serial number and
lot number control setup.

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Setting Up Lot and Serial Control
Setting Up Lot and Serial Control
Lot and Serial control is defined in Oracle

Inventory
Work order serial tracking is set in the Work in
Process Parameters window
SN0024
SN0025
SN0026
Lot 2
Lot 1
Setting Up Lot and Serial Number Control

Inventory Setup
In the Inventory Item Master window, specify Serial Control type, as Predefined. Work in
process serial tracking is only enabled when you use the value of Predefined.
Establish the type of serial number uniqueness in the Oracle Inventory Organization
Parameters window. Options are Within inventory items, Within an organization, or
Across organizations.
You can generate serial numbers using the Serial Number Generation concurrent program. This
program is accessed from a number of serial entry windows.
Work in Process Setup
The Serial tabbed region of the WIP Parameter file is where you set features for this tracking
including control beginning at the routing, association of serial numbers to jobs before their
production, serial based transaction entry, and label printing:
Default Serialization Start Operationsets the job operation where tracking begins.
Auto Associate Serial Numbers on Job Creation From Interfaceused with WIP Mass
Load for automatically generated serial numbers

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Default Intraoperation Step for Assemblydefines a default value for the intraoperation
step when moving assemblies.

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Assigning Lot and Serial Numbers
Assigning Lot and Serial Numbers
Lot 2
SN0025
SN0024
Assigning Serial Numbers

Serial numbers can be assigned, accessing Inventory functionality, in several WIP windows.
The Associate Serial Numbers window is accessed from the Discrete Jobs window. This
window enables you to generate and associate new or existing serial numbers for the job.
You can assign lot and serial numbers at completion transactions in the Work Order-less
Completions window. After accessing the Components window, select your items and
choose Lot/Serial to access the Lot Entry or Serial Number Entry windows for data entry.
During move transactions, the Backflush window appears if you are backflushing lot or
serial controlled pull components. This window provides efficient entry for large numbers
of lot and serial controlled items.
On the Discrete Workstation you can backflush lot and serial number controlled items
during completion transactions. The Components dialog window is accessed where you
can navigate to the Lot Entry or Serial Entry windows directly from the workstation. A
visual indication of the required data entry is displayed.
On the MES Workstation, the Transact Components page enables you to enter lot and
serial numbers. For individual components, select values in the Serial region. If serial

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numbers have not been generated, select Enter Multiple Lot and Serial to access the Add
Lot and Serial page in Oracle Inventory.

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Serial Number Tracking Throughout Manufacturing
Serial Number Tracking Throughout

Manufacturing
SN0024
Serial Number Tracking Throughout Manufacturing

You can track your jobs using serial control throughout the manufacturing process. Serial
tracking is only supported in the online mode using Work in Process in Oracle Mobile Supply
Chain Applications. This feature enables you to assign and associate serial numbers to a job,
and track the assembly by serial number as it progresses on the shop floor. This includes:
Serial control beginning at a specific point in the routing
Association of serial numbers to jobs before build
Serial based transaction entry
Import and auto-generation of serial numbers
You can view the genealogy of the serialized assembly including component issues and returns,
and assembly completions and returns.

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Agenda
Agenda

Summary

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The Component Pick Release program is a rules

based system for replenishing.

Component picking, obtaining requirements for specific jobs and schedules, is the process of
moving items from source locations and issuing them to work orders. The Component Pick
Release program features include:
The Component Pick Release window is used to select requirements and create move
orders for discrete jobs, lot based jobs, repetitive schedules, and flow schedules.
There is a distinct and individual window for the manufacturing mode selected.
Move orders, requests for the movement of material within an organization, are created for
picked items. They enable the replenishment of material within a warehouse or
manufacturing shop floor.
The source for material picked is based on Oracle Inventory allocation rules entered on the
Picking Rules window. If Oracle Warehouse Management is installed, you can use rules
based picking recommendations. This employs user defined rules to recommend locations
to pick from, specific items to pick, and item revisions. Pick methodologies, or grouping
rules, control how pick tasks are grouped to individual picking. Grouping rules include
order pick, bulk pick, cluster pick, and user defined grouping rules.
The destination for picked material depends on the supply type.

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Using the Component Pick Release Program (continued)

If you are using the Component Pick Release program, you can run the pick release multiple
times until the requirement is filled.
Setup
The Component Pick Release program only considers supply type push components in
processing, unless the Release Backflush Components parameter is enabled. This parameter
enables both operation pull and assembly pull supply type components in the pick release
process.
Refer to Guided Demonstration Using the Component Pick Release Program
[LAB4370Y]

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Agenda
Agenda

Summary

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Overview of Outside Processing
You can include supplier-sourced components and

resources in your manufacturing. This enables you to:
Define items that the supplier contributes in the build
process
Use specialized supplier skills
Increase your overall production capacity

Outside processing provides a closed loop system using Oracle Inventory, Oracle Purchasing,
and Oracle Work in Process to:
Define outside resource requirements for routings, and automatically charge outside
processing resource costs.
Automatically generate purchase requisitions.
Receive assembly items from outside processing suppliers.
Outside Processing Items
You can define outside processing items that represent supplier-sourced items, resources, and
services that you include in your build process. These items can be non-stocked items which
represent the actual supplier contribution in your build process, or you can define the assembly
itself as an outside processing item. The outside processing item on your requisition or
purchase order, is received in your purchase order receipts.
You can define supplier-sourced components by selecting the Supplier supply type on your
bills of material. Supplier components are not transacted or backflushed.

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Outside Processing Resources
Outside Processing Resources
Outside resources are included on your routings for

scheduling and costing. You can assign multiple
outside resources per operation.
OP 10
OP 20
OP 30

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Automatic Requisition Generation

Supplier
PO to supplier for items
OP 10
OP 20
OP 30

Work in Process automatically generates a purchase requisition for outside processing
operations, unless you specify that they are created manually. An outside processing operation
is an operation that contains an outside resource linked to an outside processing item. The
timing of the creation of the purchase requisition is based on the setting of the WIP parameter
Requisition Creation Time:
At Job/Schedule Releasea purchase requisition is created for all outside processing
operations on a job or schedule when you release the job or schedule.
At Operationa purchase requisition is created when you move into the queue
intraoperation step of an outside processing operation. You then use Purchasing's
Autocreate feature to convert these requisitions to purchase orders.
The Requisition Import process automatically runs when using PO Move and PO Receipt
resource types, but only PO Move initiates the workflow.
Instructor Note
Refer participants to the Oracle Purchasing Users Guide for information on requisitions,
purchase orders, and the Requisition Import process. A detailed description of Outside
Processing is discussed in the Special Topics lesson.

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Refer to Practice Viewing and Creating Material Transactions [LAB4315Y]

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Agenda
Agenda

Summary

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Summary
Summary
You should now be able to do the following:
Understand material requirements for production
Assign supply types to component requirements
View and update material requirements
Understand how backflush transactions creation
Assign lot and serial controlled items
Replenish items using the component picking
program
Understand outside processing in replenishment

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Updating Material

Copyright Oracle, 2008. All rights reserved.

Updating Material Requirements

Updating Material Requirements

Copyright Oracle, 2008. All rights reserved.

Updating Material Requirements

Updating Material Requirements

Updating Material Requirements

Copyright Oracle, 2008. All rights reserved.

Updating Material Requirements

After completing this lesson, you will be able to:

Copyright Oracle, 2008. All rights reserved.

Updating Material Requirements

Overview of Material Requirements

Copyright Oracle, 2008. All rights reserved.

Updating Material Requirements

Overview of Material Requirements

Overview of Material Requirements

After a job is released, you build it by issuing components.

Copyright Oracle, 2008. All rights reserved.

Updating Material Requirements

Overview of Material Requirements

Overview of Material Requirements

When you define a job, the assembly bill created in Bill of

Overview of Material Requirements

Copyright Oracle, 2008. All rights reserved.

Updating Material Requirements

Overview of Material Requirements

Overview of Material Requirements

When you define jobs and schedules, you can control

Overview of Material Requirements (continued)

Copyright Oracle, 2008. All rights reserved.

Updating Material Requirements

Overview of Material Requirements

Overview of Material Requirements

Push and Pull Requirements

Overview of Material Requirements (continued)

Copyright Oracle, 2008. All rights reserved.

Updating Material Requirements

Aligning ECOs for Work in Process and Planning

Aligning ECOs for Work in Process and Planning

Aligning ECOs for Work in Process and Planning

Copyright Oracle, 2008. All rights reserved.

Updating Material Requirements

WIP Parameters - Material

WIP Parameters - Material

The Material tabbed region of WIP Parameters set

WIP Material Parameters

Copyright Oracle, 2008. All rights reserved.

Updating Material Requirements

Copyright Oracle, 2008. All rights reserved.

Updating Material Requirements

Component Yield and Shrinkage

Component Yield and Shrinkage

Component Yield and Shrinkage

Copyright Oracle, 2008. All rights reserved.

Updating Material Requirements

Simulating a Discrete Job

Simulating a Discrete Job

You can simulate a standard job to determine what materials

Refer to Practice Inventory Material Setup [LAB42E7Y]

Copyright Oracle, 2008. All rights reserved.