Oracle Process Manufacturing Setup EBS12.2

MFG Process Setup
OPM
Oracle Process Manufacturing by MLA
Consist of 
1- Predefined Setup :
• Inventory Organizations*
• Organization Parameters*
• Sub-inventories*
• Locators*
• Unit of Measure Classes*
• Units of Measure*
• Unit of Measure Conversions
• Master Items
• Organization Items
2- Product Developments
Define Formulas, Define Routing, Define Recipes
3- Process Execution
4- Process Costing
5- Process Planning

1- Predefined Setup:
1- Create User with Responsibilities:
F11 to Open Search Mode
Enter name  Mina Followed by % then CtrlF11
Add Res:
System administrator
Purchasing Super User
Inventory, Vision Operations (USA)
Process Engineer
Formulator
Product Development Security Manager
Production Supervisor
Production Operator

OPM Financials
2- Create OU
Inventory Setup OrganizationsOrganization
Select at Classifications  Operating Unit
Make Sure to Enable it  then Click on Save
 Others
Select Operating Unit Information

Add Primary Ledger and Legal entity and OU Code
Then Save
3- Create Master Item Organization
Select at Classification  Inventory Organization
And from Other Select Accounting information
Inventory information
No ReceivingInformationfor itemOrganization

Make Sure to Add Related OU  MLOU
Set Default inventory information
Set org code and add Same Code at item master Org Code
Add Calendar

At Cost information tab
Note: Note this tab applies only to discrete organizations.
The costing organization that controls the costs in your current organization and the costing method are
displayed. You cannot make changes to these fields.
Some Default account at Org Level Can override it on Below Levels as sub
inventory

4- Create 2 Inventory Organizations (one Org as inv org -ML1- / another one as OPM Organization -ML2-)
At Organization Classification add Business Group (to use position hierarchy at Procurement)

Inventory Organization
Accounting info
Inventory information

For Process Org
OpenOrganizationParameter
Make Sure to Select Organization as
1- Process Manufacturing Enabled
2- Make sure to add Master Item Org

At Cost Tab
AutomaticallyCost Method Change to standard
Why Standard formanufacturingindustries someindustriesneedtokeepitemcostnomanychangesoccur onit
RegardingtoAverage ChangedeverytimeTransactionOccur
For standardany variance storedat variance account,and analyzedandin-case anyChange neededtoCostcan make
Cost update
To Create Move Orderat TransferitemforManufacturing

Receivinginformation
Create Sub inventories at each ORG
Inventorysetuporganizationssubinventories
Quantity
Tracked
Indicate whether each transaction for this subinventory updates the quantity on hand for the subinventory.If
deselected,on-hand balances are not maintained and you cannot select or update the Asset Subinventory option .
Note: You can update this value only if there is no on-hand quantity,no pending transaction,or no uncosted
transaction for the subinventory.

Asset
Subinventory
Select this option to maintain the value of this subinventory on the balance sheet.
Note: You can update this value only if there is no on-hand quantity for the subinventory.
Type Select a subinventory type:
 Storage: Designates thesubinventory as a Storage subinventory.
 Receiving: Designates thesubinventory as a receiving subinventory, and links it to a receiving location. This subinventory typeis
used only for receiving material. Material in this typeof subinventory cannot be on-hand, or reserved.
 Null: No subinventory designation
To override AccountsatSub inventoryLevel

5- Set Organizationaccess for AssignedResponsibility
InventorySetuporganizationorganizationsaccess

2- Product Development:
Setting Up Parameters: From  “Product Development Security Manager” responsibility
First Set Organization Access:
Enter ProductDevelopmentSecurityManagerRole toSetSome Defaults asFormal,Operation,Routingreceipt
Defaults
OrganizationParameters

‫ال‬
Defaults
‫االصناف‬ ‫بتطوير‬ ‫المتعلقه‬
handStatusin All Locators:
-
GMD: Update On
handlotinventoryin
-
Thisprofile optioncontrolswhetherthe final sample groupdispositioncanupdate the statusof on
onlythe locator specifiedatthe time of sample creation.If settothe defaultvalue,Yes,thisprofile option
all locatorsor
handinventoryexistsforthe lot.If setto No,itwill strict
-
allowsthe material statuschange acrossall locatorswhere on
handinventoryexistsforthe lot
-
tuschange to the locator where the sample iscreatedandon
the material sta
3- Create itemstouse at Formula
Change Org to Mater item Org “MST”
Openinventory itemsitemMaster
Create Finishgooditem

InventoryTab(attribute init)
Cost Tab

COGS Accountto be override onthe itemLevel
PurchasingTab
Expense Accounttobe override,itemtaxable andRequire RFQornot,invoicingMethodtoMatch

ProcessmanufacturingTab
Make sure to Select ProcessExecutionEnable
AssignitemtoinventoryOrg

Create RAW item and Assign to Orgs
4-Formulator
Create FormulaforProcessitem
OpenRes Formulator
Can SetupformulaClass,statusforFormula
Formula Classes
Formula Classes group formulas with similar characteristics and requirements for
reportingpurposes
FormulaHeaderandDetails:
Products and co-products and Ingredients must be recipe-enabled

+ CreateFormula Same AsBill of material fordiscrete items
AddfinishGood(Productand its Ingredients)
Make sure if u are usingbyProduct to be allowedFromManufacturingOrganizationParameter
Scalingallowed if itemincreaseorDecrease alsoaffectQuantitiesof ingredients
If we remove CheckBox of Scalingallow
Cost Allocation itemaffectbybatchCost

Can both standard and packaging formulas be created?
Yes. Use the Formula Details window to createboth standard and packaging formulas.
To set up a packaging formula, enter the packaged item
itself as product.Then enter the bulk item, packaging container,and package label as
ingredients.
Addingredients
To add Scrap Percent
Formula ingredients can be scaled using rules that specify whether or not an
ingredient contributes to yield.

How to Consume Material (Consumption Types)
1-Automatic by Batch CompletionConsume Material
2-Manual byEnteringManual transaction“WIPISSUE”
3-Increamentwheningredientconsumptioniscalculatedbyincrementalbackflushing.
4-Automanticbystep AfterComplete step
Contribute to Yield
Ingredientsare contribute productoutputornot
To Scale by amount or Percent

Oracle Process Manufacturing(OPM) does not calculatethe cost of production of
byproducts.Any items produced by formulas that you want tocalculatecosts for must
be entered as products
Using Formula Phantoms (Not Stored , Not Sold , Trackable)
Phantoms areintermediateformulas that arenot manufactured as products.Phantoms
are sometimes referred to as transient subassemblies.
Two fundamental tasks are associated to using phantoms are:
• Identify one or more ingredients in a formula as phantoms.Use thePhantom Type
field to indicatethat an item is a phantom.
• Build a formula for each phantom.The method for building a formula that
generates a phantom is the same method used to build a formula for a regular
batch.The formula ingredient must be defined as a phantom
Phantoms You Make
Use a basic bread dough for a number of kinds of bread. You do not sell it or keep it in
inventory,however you need totrackits ingredients.Your formulas for bread contain
#BASICBREAD plus whatever other ingredients areneeded to turn plain whitebread
into other kinds of bread such as rye, wholewheat,and pumpernickel.
In this case, you need only one version of the#BASICBREAD formula.

Scaling Formulas
You can scale formulas up or down by input or by output
Following are the ContributetoYield types availablein Product Development:
• Yes indicates that an ingredient contributes toyield.
• No indicates that an ingredient does not contributetoyield.
Scale Type Definitions
The quantities of items which arefixed scale are not altered when a formula is scaled.
For example, if a formula has a fixed scale ingredient with a quantity of 10 kg and the formula is scaled by a factor
of two,then the quantity remains fixed at 10 kg.
115:120 ‫عمل‬ ‫لما‬Scale by 2
‫كل‬ ‫بمعنى‬
115
‫بتحتاج‬ ‫النهائي‬ ‫المنتج‬ ‫من‬
120
‫الخام‬ ‫المواد‬ ‫من‬

Mixed Type Scaling: Fixed and Proportional With Yield Contribution

Mixed Type Scaling: Proportional With Yield Contribution and Fixed Without Yield Contribution
UnderstandingInteger Scaling ‫تتجزأ‬ ‫ان‬ ‫يمكن‬‫ال‬ ‫قيمه‬
Some material in process industries is picked from inventory in eaches, such as a 30 pound bag of defoamant or a
box of antistatic sheets.If an item is issued in 30 pound bags,then it is supplied in full bags and managed on the
production floor appropriately.If the UOM used in the formula is the bag, then you must scale in whole
integer increments.If you want toexpress the ingredient in pounds, then integer scaling is not sufficient. You
need a way to specify that theingredient must only be scaled in multiples of 30 pounds.
When materials arescaled by a multiple, a scaling direction value must be specified so that the scaled quantity is
rounded properly. Scalingby a multipleresults in ingredients being rounded up or down to the next whole
multiple specified for the item in the formula. It is possible that theformula ingredient is not scaled as a result of
not meeting the criteria toround up or down. Rounding Varianceis required for integer scaling. If you do not use
rounding variance,then scaling typedefaults to proportional scaling.

Decision Even 25 or 50
Scale percent1.6  Required Qty. = 25*1.6 =40
Low 25 Req. 40 Up 50
Variance 30%of Req. Qty. =12 KG Direction Down
Variance between 25-40=15 >12
Variance between (40-50) =10 and regarding there isUp Direction So Scaled Qty. Will Be
40

Disabling the Scaling of a Previously Scaled Formula
This advice applies to the Formula Details window.
If you clear Scaling Allowed so that scaling is not allowed on a formula, then the following
message displays: Unchecking 'Scaling Allowed' for this formula will change the scale type for
all material lines to fixed. The minimum, maximum, and standard quantities for any existing
validity rules will be changed to the product quantity in the formula.
Copying a Formula
Use the Copy Formula window tocopy a preexisting formula into another organization.
You can assign a new formula name and version to the copied formula. The
organization must haveaccess to theitems defined in the formula. Use the copy
formula function to create customized formulas for use in general, site, master,and
control recipe type
Item Conversion to GMD YIELD TYPE does not exist upon scaling batch with
fixedingredient. (Doc ID 1369756.1)
Upon attemptingtoscale a batch, errordisplays:ItemConversiontoGMD YIELD TYPE doesnotexistforthe
item/itemsinthe Recipe/Batch.Cannotscale/create batch.
Why isthishappeningonlywhenafixed,non-contributingtoyielditemexistsinthe batch?

Perdesign,if there are anyitemsinthe formula/batchwithafixedscale type,youare thenrequiredtohave
itemconversionsexistforALLthe otherscalable itemstoparameterYIELD UOM whichissetinProduction
DevelopmentSecurityManager>OrganizationParametersunderthe Formulatab
Calculating Formula Product Quantities:
Formula Product Quantity = [(Sum of Contributing Ingredients Quantities)
– (Sum of Byproduct Quantities)] * [(Percentage Entered for Product) /100]

5-Process Engineer Res.
Operationsare depictedhierarchicallyinthe followingdiagramthatshowsthe:
• Routingcomposedof aseriesof OperationsorganizedinSteps.
• Operationscomposedof ActivitiescontainingResources.
• Formulacomposedof Ingredient,Product,andpossiblyByproduct.
• Recipe linkingthe RoutingandFormulatogetherwithProcessingInstructions.
To Create ActivitiesandResourcesandOperationsWhichUsedatRouting
A-Create Activity
OpenProcessEngineerRes SetupActivities

Create Resources
Define laborandmachine
- Process Operations:‫معينه‬ ‫مرحله‬ ‫اخلص‬ ‫بعملهاعشان‬ ‫اللى‬ ‫النشاطات‬ ‫مجموعه‬
Set of activities that havetobe completed for a predetermined step in a production batch.
Resource requirements that areneeded to perform these activities areusually specified. You build
operations from activities that requireresources

The Process Operation Details Activities window links operations to activities.
Create Operations WhichContainActivityandResources
Add activity at operation and at Activity factor add no. of time you do this Activity
Save an operation that contains activities with no associated resources if the operation
status is New. Status cannot be changed to Approved for Laboratory Use or to
Approved for General Use until all activities have resources associated to them.
Add Resourceto Operation
SelectResource and quantityProcessperHour
Here it means
To identifyNoof Resource fromCount
Worker Produce 10,000 SUP per hour

Create AlsoAnotheroperation
Define ProcessQuantityUOM“Importantto Calc hours basedonProducedQty”
Here I defineditWithKG
AnotherProcessCanbe Definedby

Save Operations
6- Create Routing
OperationSequence toProduce Aspecificitem

Displaying Theoretical Process Loss
Theoretical Process Loss can vary depending on therouting or theindividual quantity
being processed by a routing. This loss is defined at the routing level and is based on a
minimum and maximum range of quantities.
The Theoretical Process Loss window enables you to enter the hypothetical percent loss
expected for a range of material processed during a specified routing. For example, if
you mix a quantity of material up to 100 pounds, then the predicted loss might be 1.50
percent, or up to 1.5 pounds. However, if you mixed a quantity between 100 and 500
pounds, then you might predict a loss of 1.75 percent theoretical process loss, or up to
8.75 pounds lost. The loss could be attributed toequipment, evaporation,or any other
aspect of the routing that detracts from thedelivery of the full quantity of material
added.
EnteringRouting Step Dependencies
Use the RoutingStepDependencieswindowtocreate andmodifyroutingstep interrelationships.Stepdependencies
are those relationshipsbetweenroutingstepsthatestablishwhetheraspecificstepcanor cannotstart until another
stepiscompleted Routingstepdependenciesreducethe routingdevelopmenttime byestablishinga defaultsequence
for operationstepsduringaproductionrun.Stepdependenciesare implementedatthe routingmaintenancelevelto
enable automaticstepquantity calculationinrecipes.
You can define newdependenciesordelete the unneededones.Forexample,if step10
isBAKINGand step20 is the COOLINGstep,thenstep10 mustbe completedbefore
step20 can begin.Bythisdefinition,step20is dependentonthe completionof step10.
Stepdependenciesare usedtocalculate plannedstarttimeshowever,theycanbe
overridden.Avoiddefiningcircularreferences,forexample Step10islessthanStep20
islessthan Step10.
UnderstandingRoutingStep DependencySelections
StepDependenciesare definable as:

• Finish-to-startwithnooffset,toindicate aprocessstepbeginsimmediatelyafterthe completionof itspreceding
step.For example,aconsecutive additionof ingredients isrequiredwithoutinterruption.
• Finish-to-startwithpositive offset,toindicate a processstepbeginsaspecified periodof time afterthe completion
of itsprecedingstep.Forexample,time is requiredtorestmaterial before the additionof anotheringredient.
• Finish-to-startwithnegativeoffset,toindicate aprocessstepbeginsaspecified periodof time before the
completionof itsprecedingstep.Forexample,a productiondeviceneedsto be activatedbefore the additionof the
nextingredient.
Start-to-start with nooffset, to indicatea process step begins at thesame time as the step it depends on. For example,
thereis a need for simultaneous addition of ingredients without interruption.
• Start-to-startwith positiveoffset, to indicate a process step begins a specified timeafter the beginning of its preceding
step. This is similar tofinish-to-start with negativeoffset, but by specifying that the dependency is start-to-start,you can
ensure the positiveoffset is maintained if the previous dependent step finishes early.
+++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++

7-Create Recipe
Recipes standardize the structure of all information that describes production of one or more products.
 To provide thegreatest flexibility to process manufacturers,formulas and routings arebuilt independently. They
are linked using a Recipe that has validity rules” ‫الصالح‬ ‫قواعد‬
‫يه‬ ”. Different formulas can use the same routing, or one
formula can be associated to several different routings.
 A recipe can be created in one inventory organization and then copied, modified and maintained by another
inventory organization.
Recipe ‫اضافه‬ ‫عن‬ ‫عباره‬ ‫هتكون‬ ‫الخلطه‬
‫ال‬
formula
‫وال‬
Routing
‫هستخدمها‬ ‫اللى‬

Recipe Details window:
* Recipe Organization Details
• Recipe Validity Rules
:
• Recipe Step/Material Association
Recipe Step/Material Association to display all items from the recipe's formula and associatethem with specific routing
steps
Validity Rules:
Make Sure to CheckValidityRules

Validity Affect Planning Incase Formula not Scaled (Std,Min,Max) will be Not Editable so FOQ have to equal Standard
If FormulaScaled Will be Editable (Standard : Batch Size, Min , Max have to be greater than Biggest Planned Order )
- Enter the UOM as unit of measure for the standard quantity.Required.
- Enter the Min Qty as the minimum quantity of material allowable by thevalidity rule.Required.
- Enter the Max Qty as themaximum quantity of material allowableby thevalidity rule.Required.
Enter the Preference number for the validity rule. When more than one formulacan be used to produce the same product, the Preference field is used to
show the validity rule that must be used first, second, third, and so forth. Preference defaults to 1. Required.
AlwaysMake Sure to Change Statusto Approve forGeneral Use
Action Change Status
ThenSave
Understanding Step Quantity Calculations:

Entering Recipe:
- EnterRecipe Name,associate byFormula,Routing

-The output Quantity displays thesum of the product quantities entered in the formula. UOM is the unit of measurefor
the formula associated with this recipe.
Enter Recipe Type as:
- Select Contiguous if routings in this recipe must be run in one contiguous block of time. The batch that uses this routing
cannot stop and start,even if it runs into downtimeon the shop calendar.
-Enter the Planned Process Loss as the loss of process material observed during production of a batch usingthe recipe. If a
value is not entered in this field, then it defaults to the value entered for Theoretical Process Loss.
Displaying the Recipe Step/Material Association:
Use the Recipe Step/Material Association window todisplay all items from the recipe formula and associatethese items
with specific routingsteps.

Which mean this Material consume at this Process

PROCESS EXECUTION
OPM Process Execution parameters  Using “Production Supervisor”
From It Create Bach and control batches, Simulator and Setup Defaults for Production Process
Execution Parameter:
SetupParameter

To add(SelectProcessOrganization)
1- Batch SetupTab
- DisplayUnconsumed/UnyieldedMaterial to view the unconsumedingredientsandunyieldedproductswhenabatchis
complete.
- Allow Material Deletion “At batch status pending”
2- Create Batch
- CheckMaterial shortage or not “inventory organization level”
- Select Copy Formula Text to copy text from the formula header and details tothe batch header and details during the
batch creation process.
AllowHighLevel Reservation  notpreferred tobe selected toavoidReservationbefore Release WorkOrder“Batch”

Select Create Move Order to create move orders during batch creation for theingredients that do not havesufficient
inventory in the supply sub-inventory//+//In-Case using WIP Sub-inventory for transfer material to” ‫للمواد‬ ‫وسيط‬ ‫مخزن‬ ‫وجود‬
‫الخام‬
”
Auto Detail Batch: Create Reservation / Release Batch /Create and Release Batch
3- DocumentNumbering:
4-InventoryTransactionTab

At thiscase didnot specifySpecificSupplySub-inventory,soitwill reserve fromanysub-inventoryContainMaterial
Else CouldI setspecificsupplySub-inventoryWIPandMaterialsMovedfromRMand PACKto WIP thenconsume to
Batch
- Select Auto-consume From Supply Sub-inventory Only toconsume ingredients automatically only from thesupply sub -
inventory.
- Select On-hand Sub-inventories/Locators Only to display only those sub-inventories and locators with on-hand
inventory.
To Select Default Supply and Completion Sub inventories for Process Org

+Setting Up Make to Order Rules+
The Make to Order Rules window enables you to define rules for creation of Production, supply in responseto a sales
order through a batch or FPO.
-ProductionSupply  BasedonSalesOrderWhat’sthe Reflectonproduction(Create BatchorPlannedOrder)
-Select Check Availability ifyou want theapplication to check for on-hand inventory beforecreatinga batch.if you do
not -select the check box, then a batch is created for theorder quantity irrespectiveof the on-hand quantity

Select the Firm Indicator to prevent the Advanced Planning and Scheduling (APS) engine to reschedule the batch.This
is not enabled for firm planned orders
Make Sure to SetCorrect Shipto Site
Create SalesOrderandBook it

Make Sure to be all itemattribute Correct
1. MO: Set Client_Info for Debugging
Set the value of the Profile Option "MO: Set Client_Info for Debugging" to 'Yes' for "Production
Supervisor" responsibility.
Note: This profile setting is no longer needed unless you are running old code.
2. Enable workflow event oracle.apps.gme.batch.reservation and its Subscriptions
Path :Workflow Administrator event manager.
3. Make sure that following setup points are achieved for the product item to be ordered through
sales orders:
It is an inventory item
It is OE Transactable
It is Process Execution Enabled
Before Running
Make Sure to SetEvenDoc (BatchNumberingorFPO) to Be AutomaticnotManual

ThenFrom ProductionSupervisorRunRequest :“ProcessManufacturingMake to Order”
Parameters:
Org Unit
OrderNo,Customer,Item,Warehouse
TO check RequestResultyouhave toopen“View Log”toshow CreatedBatch

Batch 10 has beencreated
CheckCreatedBatch

Planned Orders:
Firm Planned Orders This topic also discusses how to convert the firm planned order to a batch
Firm Planned Orders are designed for medium and long range production planning.
Creating a Firm Planned Order
You can Create Planned Order from
1-From ASCP Planner workbench
2-Create Batch/firm Planned Order application
While adding item at product output at Creating Batch and no Data found “Make Sure Recipe is approved for General use ” “No
need for MFGmodule to Set profile item Validation Organization”
Finding a Firm Planned Order
You Can Find Planned Order by status or Document No. or Dates

Status Exists are :
You can edit text, convert the firm planned order to a batch,cancel the order, rerouteor reschedule, and scale the firm
planned order.

To convert to Batch
Tools  Convertto Batch
To Cancel or Reschedule or Reroute
In case there is Shortage at sub-inventoryLevel will be shown while creating Batch

Batch Created by No.2
Batch Creation
Inventory Structure at OPM
Inventory Organization
Inventory Organization is a plant wherethe batches areproduced or an organization that holds the inventory at specified
locations.Offsite warehouses and distribution centers arealsodesignated as inventory organizations.For example: Plant
P1, Offsite Warehouse W1,Distribution Center D1.

Subinventory is a subdivision of an inventory organization representingeither a physical area or a logical grouping of
items, such as a storeroom or damaged inventory.
Inventory balances aretracked here. Reservations can be placed against inventory at this level. Items can be restricted to
certain subinventories.Asubinventory can alsobe a division of a warehousethat holds inventory with similar planning
and reservation characteristics.For example, stagingarea, manufacturingarea,and distribution center.
Supply Subinventory is thesubinventory from which theitems required for batch production areconsumed It can be the
shop floor or a staging location.
Process loss is the material lost or is unrecoverablein a production step, due to factors such as evaporation or
changeovers in production processes. Lost materials need to be planned for to achievethe targeted process quantity for
steps. The loss can vary depending on the material beingprocessed. Therefore, a production loss factor can be defined at
the routinglevel and this loss must be reflected in both planning for and production of ingredients associated with a
particular step.OracleProcess ManufacturingProduct Development enables the entry of process loss factors to facilitate
better material planning.
There is 2 type for Material Loss “‫التخطيط‬ ‫ف‬ ‫واضح‬ ‫بيكون‬ ‫”تاثيرهم‬
1- At Formula Level  Scrap Percentage “ ‫الخام‬ ‫الماده‬ ‫من‬ ‫تالفه‬ ‫نسبه‬ ‫وجود‬ ‫احتماليه‬
–
‫تالفه‬ ‫عبوات‬ ”
2- At Routing Level  Loss While Processing
At Routing Level:

Theoretical Process Loss:
‫فيها‬ ‫بتتصنع‬ ‫اللى‬ ‫الخام‬ ‫المواد‬ ‫من‬ ‫ايه‬ ‫قد‬ ‫معايا‬ ‫بتهدر‬ ‫نفسها‬ ‫العمليه‬

Batch Status:
Actions menu:
• From Pending to Work in Process, select Release.
• From Workin Process to Pending, select Unreleased.
• From Pending or Work in Process to Completed, select Complete.
• From Completed toWork in Process, select Revert to WIP.
• From Completed toClosed, select Close.
• From Closed to Completed, select Reopen.
• Select Terminateto terminatea WIP batch.
• Select Cancel to cancel the batch or Firm Planned Order.
Change batch step status on the Batch Steps window. “Relation between Batch Status and Step Status”
* Pending batches can only have batch steps with a status of Pending
* Workin Process can have “Pending, WIP, and Completed”
* Completed batches can havebatch steps with a status of Completed or Closed.
* Closed batches can only havebatch steps with a status of Closed
Terminatinga batch cancels any remainingpending steps.

Process Order
Create Document Work OrderManual Generation
ProductionSupervisorCreateDocument

ThenOk  if there isany Shortage  Shortage FormWill AppearwithItemcontainShortage
PressOkto Create Doc
If there is more the Approve forGeneral use Recipesyouhave toSelectOnlyOne Whichusedatprocessingbatch
Substituting Items During Batch Creation:
At creating Batch in case Sub item Exist  OPM automatically provides the Item Substitution for Batches concurrent program to
update the batch and replace the original item with the substituteitem
WhilePending batch and Sub item Created  not updated automatically itneed to Run Item Substitution for Batches concurrent
To update subitemwithoriginal one
The ValidatePlan Dates parameter validates theplanned start dateand planned completion date against thevalidity rule
dates used for the batch.Dates cannot be outside the date range defined on thevalidity rule.

Rerouting a Batch:
Reservation:

1-Check Shortage on Inv. Level and Org Level
Sub-inventoryLevel
Org Level
No Shortage at org Level (meansthere isavailable onhandatanotherSub-inventoryotherthanSupplySub-inventory
AddOn handfor Material and Make Sure to add Costfor itemsandTransferneededQty.toProcessMFG

PendingLot:
To Create Pending Lot for Product
Enter Product Tab(Select Pending Lot
If you Save and CheckLots at inventory

withoutOriginationDate onlyLot
CreatedforitemwithDefaultstatus
and no ExpiryDate assignedfor
pendingLot
Reservation
High Level Reservation:
SoftReservationwithouthardcommitperinventory,Location,Lot “NotRecommended”

Reserved Qty. Change from Planned to Reserved
Detail Level Reservation “Recommended”
Hard CommitInventorywithLocationandLot

In case we using andnot available on-handonit,afterAutoBatch Detail noReservationexist
So we have First
Picking:to Create Move order from material sub to WIP

ClickOnRequirement
SelectNeededBatchtopick material forReservationthenPickMaterial
Move OrderCreatedbyrequiredMaterial

OpenInventory Res.
Move Order  TransactMove Order
If we try to find Move Orders to allocate and Transact No MaterialFound

The Problem Because Of Picking Rule not suitableto Plant
Solution
Create New Picking Rule and Assign it to Your Organization

At Assignment

Thenat OrganizationParameters:
Open Production supervisor Res.:

OpenInventory Move order Transact Move Order
To adjustallocatedLots

View/update allocation
SelectLot/Serial toadjustLot
ThenTransact

If I usingPicking PickedQuantityWill be ReservedAutomatic
To CheckOn-handat all Levels:
SelectLine Material Summary

Mass Batch Transactions:
To manage Transaction on group of Batches at the same Time

SelectBatchesandthenSelectNeededAction

Release Type forStep
Can Checkfrom(Other) Tab
Release Type (Automatic)  meansbyChange BatchStatusAutomaticallyStepStatusChanged
From Activitieswe canassignActual laborand Machine hours (AfterCompleteBatch)

Release Batch
To change Batch Status from Pending to WIP by Release it
If Material Release Type “Automatic”Will Issued Automatically by Release Batch,if “Manual” have to Transact Material
afterRelease byPerform WIPISSUETransaction

Batch Status Changedto WIP andTransactionMaterial buttonActive to PerformTransactions

After Transact MaterialManualby WIP issue

Material Reserved Qty. converted to Actual Qty.
+++++++++++++++++++++++++++++++++++++++++++++++++++++++++
Material Transactions:
Transaction dates do not update if you change the:
• Actual start dateafter releasing a batch.
• Actual completion date after completing the batch.
• Ingredients:
• WIP Issue: Issues ingredients from inventory tobatches tofulfill material requirements.If you issue lot -controlled
ingredients, then identify the lot numbers to issue.
• WIP Return: Returns ingredients from batches to inventory.For example, when you unreleased a batch it does not
consume the ingredients and returns them to the inventory.WIP Returns reverseWIP Issues.
• Products:
• WIP Completion: Issues the products produced from the batches to the inventory.
• WIP Return: Returns the products from inventory tobatches.For example, if you accidentally complete a batch and
revert backto WIP, then the inventory returns theproducts.
To view move orders:

To showMove orderno usedat pickingmaterial fromRaw subto WIP

Material Summary  To CheckMaterial On-hand
ViewMaterial Transactions
To showtransactionhistoryforBatch

To Create WIP Return
OpenMaterial Transaction

Create WIPReturnTransaction
TargetedQty.= 8 , TransactedQty.=7.9 , Exception=remainingQty.=0.1
ThenTransact
CheckMaterial Transactionnow

AfterCorrection:
The Material Exceptions window:

Window Show Automatically when:
1- Release a batch and any ingredients with a consumption typeof Automatic and are not fully transacted.
2- Use incremental backflushingand the quantities that arebackflushed and arenot fully transacted.
3- Complete a batch and have not transacted any of the ingredients, products,or byproducts in the batch.
While Batch Completionand there is RemainingQty. at ExceptionQty.  Exceptionform will be shown
Material ExceptionFormWill appearincludingunconsumedMaterial andnotCompletedFGas below
Can fromit PerformWipissue forMaterial andproduct completion

Entering Pending Product Lots:
For Product and byproduct item, I can create pending lot for upcoming Batch
From Batch Detail Open Product tab

Generate Lot and Allocated Produced qty. for this Lot

Batch Production
(A) Release Batch :
*Create Batch  from Action Release
Release Convert Batch Status from “Pending” no
transaction can performed on it to “WIP” Batch Ready for
transactions
*Enter Actual start Date for Batch
The application checks for the validity of the batch validity rule,and advises you, if the actual start date
entered in the dialogue is outside the validity ruledate range. The application checks for ingredient
reservations tocreatetransactions.If inventory shortages exist,then those ingredients are reported as
exceptions.
For a production batch or a laboratory batch with Update Inventory indicator set to Yes, the application checks lot status
and expiration dates, checks for inventory shortages, completes transactions, consumes the ingredients marked for
autoconsumption, and updates the WIP planned, planned and actual quantities.

** Batches at Pending Status **
Reserved,Picked,Release,Completed,canceled but not
transacted

** Batches at WIP Status **
Transactable
If manual transaction for ingredients and product
Then after convert Batch to WIP
Transact Materials

To Add Actual hours for Labor and machine

Current Activities Per Operation
Estimated time for Resources

Enter Actual hours per Resource

Complete Batch
From Action  Complete
Require to Enter Complete Date for Batch
And Will Open Exception Formfor unconsumed material
or un-yield products

Exception Form
Unconsumed material Exist
Steps status will updated while it’s automatic

Revertto WIP
If yieldis automatic will Revertedby Revertto WIP
From ActionRevertto WIP
Closing a Batch

Batch after Close
Can Reopen Batch fromAction Reopen Batch

(B) Unreleasing a Batch
Once a batch is released, you can to revert its status from Released to Pending. Completed transactions arereversed,
actual values are reset to zero, and inventory is updated
“All Committed transaction Reversed”
Warning message to confirmRecreate Reservationand Pending
Lot for this Batch

All transactions has been Reversedand Reservation,Pending Lot
Recreated
Warning When Yielding Batch Material into an Existing Lot

Define consume type and yield type by incremental
‫بعمل‬ ‫لما‬ ‫دى‬ ‫الطريقه‬ ‫خالل‬ ‫من‬
Complete
‫الكميات‬ ‫استهالك‬ ‫بيتم‬ ‫النهائي‬ ‫للمنتج‬
‫الخام‬ ‫المواد‬ ‫من‬ ‫المنتجه‬ ‫للكميه‬ ‫المناسبه‬
Incremental backflushing lets you record production output or yield incrementally as it occurs prior to batch
completion, theapplication calculates theingredient usage by backflushingthe ingredients based on product yield and
WIP planned quantities.
- Incremental backflushingcan only be performed on batches with a status of WIP or Completed.
- Items must have a consumption typeof Incremental to be backflushed by incremental backflushing.
Assign yield type as Incremental

You will be able to do incremental backflush only if batch status
is WIP or completed

Material Exception Window will be shown

Product at Batch after incremental backflush
Material at Batch
product is not reserved. Each timea new lot of the product is yielded, the lot number and quantity produced is reported.

Batch Completion:
Completing a batch indicates the batch is finished and has yielded all of its products Prior to batch completion,
transactions associated with the product and byproduct lines set for automatic yield have a Pending status
When you complete a batch, the Material Exceptions window displays the remaining reservations and pending
product lots. If you select the Display unconsumed/Unyielded Material parameter, then the
unconsumed/unyielded materialsb also display.
“All Transaction has been completed”
OPM Financial
Cost MethodsUsedat OPM (Standard,Actual,Lot Cost)
Defining Costs:
Can Define Costby Multiple Level
1-item
2-inventory Org

3-CostCalendar and Period
4-Multiple Cost Types (previously referred to as Cost Methods)
5-Cost Component
The unit cost of an item is usually broken dow n into severalbuckets that are attributed to various sourcesthat formthe basis of the cost
(‫التكلفه‬ ‫اساس‬ ‫او‬ ‫التكلفه‬ ‫)مكونات‬
Cost Component Classes identify individual buckets or component costs that make up the total cost,for example, direct material costs,
freight costs,labor costs,and production or conversion costs
The cost component classes are classified into 5 different elements or usages:Material, Resource, Overhead, Expense Allocation, and
Standard Cost Adjustment types
Analysis Code
component class can be further broken down using cost analysis codes for more granular tracking of cost
Allocating General Ledger expense is a method by which you can distribute the indirect expenses of manufacturing (such as
administrative and general expenses) to item costs
The balances in the expense accounts are distributed to item(s) based on either fixed percentages ordynamically derived usin g other
General Ledger account balances
Monitoring Costs
OPM Cost Management provides several reports and inquiries to monitor and analyze costs:
• Item Cost report
• Allocation report
• Sub-ledger reports
• Lot Cost History report
Simulating Costs
OPM Cost Management provides the following simulations, and lets you establish
"what if" scenarios:
Actual Costs of items are developed using the actual business transactions.The product
costs are not based on the formula, routing and recipe details but rather based on actual
consumptions of materials and resource usage recorded in the production batches
Expense Allocations
Overheads
Expenses accrued in General Ledger can be allocated to specific items as indirect
overhead costs.
You can assign and apply overhead costs to either raw materials or finished goods.·1 he
overhead cost calculation for actual cost rollups is identical to that used for standard
cost rollups
Setup OPM Financial:
1- SetupCostType
OPM financial SetupCost Types
Able to Create More than one cost type as (Actual, Standard, and Lot-Cost)
While Using Actual
You have to SelectWay to Calculate Material and FG Cost

ThenSave
2- SetupCostCalendar
SetupCostcalendar
The costing calendar is completelyseparate fromthe fiscal calendar and the periods
Therein. Cost Calendars support multiple legal entitiesandcost type.

AddCalendarName andDescriptionandStart Date then Save
ThenfromAssignments
AddL.E andCreatedCostType
ThenSave
Period Status to open Targeted Costing Period

To Close Period  FromActionthen  Close Period
3- DefiningComponentGroups:
Component groups lets you collect specific material and or resource component costs for category groupings (for example,
material costs and resource costs)
4- Cost ComponentClass

Considered as Lower Level of Cost Component to be more analytical
In a particular formula, you have two ingredients: one is a dry raw material (assigned a component class code called and the
DRYMAT other is a solution (assigned component class SOLMATL). When you view the product costs,the Item Cost
window shows DRYMAT and SOLMAT as the cost components,each with its respective cost

5- DefiningCostAnalysisCodes
‫اقدر‬ ‫اقسم‬ ‫التكلفه‬ ‫على‬‫انواع‬ ..‫سواء‬ ‫كانت‬‫تكلفه‬ ‫مباشره‬ ‫او‬ ‫غير‬ ‫مباشره‬
Cost component class can be further broken down using cost analysis codes for more granular tracking of costs.
As Material

6- DefiningCostingOrganizationAssociations
OPM maintains separate item costs foreach inventory organization. However, you can have a situation in which multiple
inventory organizations transact the item, but the item costs in all of those organizations are the same. In such cases,OPM
lets you create a costing organization and share it with other inventory organizations.
OPM lets you associate a single costing organization with multiple inventory organizations through costing organization
Associations
7- DefiningFiscal Policies
SelectLegal EntityandLedger& currency thanadd ValuationMethod
Assign Valuation Method

EventFiscal Policy
8- Define percentageoverheadcodes
To add percentage evenforMaterial itemorforFG item
Applied to Item and added to itself (that is, Direct or Production)
Applied to Ingredient but added to Product (that is, Consumption)
9- Define Resource Cost
OPMfinancial(Resource Cost
10-DefiningFixedOverheads
Use the FixedOverheadswindowtosetupand maintainoverheads.A overheadisacostassociatedwitha
resource otherthanthe resource usage assignedinthe routing.

Assume youneed alaborerto cleanMIXERl after eachuse.To account for the cost of cleanup,insteadof adding
anothercomponentcostto eachitemthat usesMIXERl,youcan assigna overheadtothe itemsbeingproduced
by that laboreronMIXERl.The overheadassignmentwouldbe the time ittakesthe laborertocleanMIXERl
multipliedbythe costperhour forthe laborer.1naddition,youcan addother costsintothe overhead(forsuch
thingsas cleaningagents).
- Enter the Hemcode forthe product or intermediate towhich thisoverheadis
assigned.Forexample,if the productBlue PaintusesMIXERl asa resource,andyouassigna overheadfor
cleanupof MIXERl to the processformakingBlue Paint,thenenterthe itemcode forblue paint.
- Enter the number of this resource used in the production of the item in Resource Count. For example, if it takes one
laborer to cleanup MIXER1 after each use, thenenter1 (laborer). lbis number is multiplied by the Resource Usage
to calculate the total resource usage
Using Actual Costing
Actual costs cannot be entered manually using theCost Details window.To enter costs
for the first period for Actual Costs, use the Item Cost API to load thecosts
Does actualcostsupportinvoice override ofreceipts?
Yes. Actual cost uses the invoice price, if available,and the invoice price is preferred
over the PO pricein cost calculations
Understanding Actual Costing
OPM captures the actual costs from business transactions.Costs of raw materials are
captured based on the raw material purchaseorder receipts and or invoices. Costs of
products are captured based on the actual quantities of the raw materials consumed
and the resourceusage or conversion cost recorded in the production batch
Overhead Costs
Overhead Unit Cost is calculated by dividing the Item Quantity intothe sum of --
Overhead Usage, multiplied by Overhead Quantity,multiplied by Resource Cost, as
shown in the following illustration.
Expense Allocations
You can take an expense amount and allocate it through to multiple raw materials or
products on a percentage basis.You can perform any last minute adjustments to
allocations prior to Actual Cost calculations.
Ensure that expenses areallocated in the correct period and that batches arecompleted
and closed in thesame period.
Another alternativeis to enter the account balances into OPM manually using Cost
Allocation Maintenance.

The Average Cost Adjustment typelets you enter a quantity and a cost. This adjustment
simulates a transaction that happened outside theOPM Actual Cost process

Production Batch Costs
Actual ingredient usage from Production is captured for closed batches.Ingredient cost
is calculated by the actual cost raw material method for your cost method.
Actual resourceusage, count, and throughput arecaptured in the OPM Process
Execution application.Resource rateor nominal cost is entered in costing.
Batch unit cost is calculated by dividing -- thesum of ingredient quantity,multiplied by
the ingredient actual cost, plus the sum of resourceuse multiplied resource rate -- by
the batch item quantity,as shown in the following illustration:
Production Batches
In Process Execution, when a lab batch is created you can specify whether toupdate
inventory by checking the Update Inventory box. If you do not check this box, then the
work-in-process inventory organization is set to null. In this case, no inventory
transactions arecreated and theActual Cost process ignores these batches in cost
calculation.As a result, thevariances arenot calculated.
Product Transfer Example 1: Product transfer from production inventory organization to a distribution inventory
organization
In this example, the cost for the product PROD-A is as follows:
Production Inventory Organization:WHS1
• Cost: $5.00 per LB
Inventory Balance: 200 LB
Distribution Inventory Organization:WHS2
• Cost: $6.00 per LB
Inventory Balance: 500 LB
Transfer 100 pounds of product PROD-A from the production inventory organization
WHS1 to distribution inventory organization WHS2. The inventory transfer originates

from WHS1, thereis no impact on the cost in that inventory organization.Cost is
impacted at WHS2 as shown:
• Cost at WHS2 = (Previous Balance * Previous Cost) + (Transfer Qty * Unit Cost at
WHS1) / (Previous Balance + Transfer Qty)
= ((500 * $6) + (100 * $5)) / (500 + 100) = (3000 + 500)/600 = $5.8333 per LB
Setting Up Expense Allocations

Oracle Process Manufacturing Setup EBS12.2

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