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Oracle Process Manufacturing

Implementing Oracle Process Manufacturing

Craig MarmonDeloitte-Touche

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First of all, What is OPM (i.e. the product formerly known as GEMMS)?

• On July 20, Oracle announced the GEMMS product suite will now be referred to as Oracle Process Manufacturing (OPM).

• OPM is designed exclusively for process manufacturers– Consumer Packaged Goods

• Food, Beverage, Health and Beauty, Household Products

– Industrial Products• Chemical, Pharmaceutical, Petroleum, Metals, Mining,

Paper and Glass

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OPM coverage is similar to the Oracle Discrete Manufacturing product suite

• Inventory• Purchasing• Order Fulfillment• Formula• Production• Process Operations Control• Costing• Quality• Physical Inventory• Laboratory• Material Requirements Planning• Master Production Scheduling• Capacity Requirements Planning• EC Intrastat

• Inventory• Purchasing• Order Entry• Bill Of Materials• Work In Process

• Cost• Quality

• Material Requirements Planning• Master Production Scheduling• Capacity

OPM Modules Discrete Equivalent

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OPM is currently written in the JAM toolset from JYACC.

• The current version of OPM is 4.10.06. It is integrated with Oracle 10.7

• It is available in GUI only as a SmartClient.• The term ‘SmartClient’ is an oxymoron. It is

highly suggested to use Citrix WinFrame as the client interface.

• Version 11.0 due in December will be written in Developer 2000 and be integrated with Oracle 11.0 NCA

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OPM Release 4.1 Review

• First Delivery - September 1997 – Year 2000 Compliance– Integration to Oracle Financials

• 10.7 SC• 11.0 in November, 1998• Multi-company support

– Advanced Order Processing– Inventory and Manufacturing Enhancements

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OPM Release 4.1 - Patches Through 06

• All ports released• Intrastat support• Upgrade i2 integration to 2.9 release

– Oracle OPM Rhythm Capacity Planner– Oracle Rhythm Factory Planner

• SOP improvements– Usability Team

• Multi-user batch usage• Oracle Financials 11 scheduled for Q4

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OPM Release 4.1 - Decision Support

• Discoverer• Reports 3.0• Oracle Express - OLAP

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The approach for design and deployment is not unlike other ERP applications

As-Is and To-Be phases can range from 6 weeks to 6 months depending on the amount of change the client requires (i.e. systems replacement versus

Reengineering). Most often GEMMS can be implemented in 6 to 10 months start to finish.

Testing and Testing and DeliveryDelivery

FastTrack4 Oracle

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The first implementation step is to establish a test and development environment

• The testing environment is intended as a ‘sandbox’ for the project team to play

• The development environment serves as a test bed for new patches and upgrades– Oracle typically releases GEMMS patches every

quarter and a major release each year

• A training environment may be necessary as regularly scheduled classes are too few and far between

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Confirming business requirements through testing is extremely important

• Moving from ‘To-Be’ to ‘Will-Be’ requires confirmation that the processes can be performed in the system as designed.

• Using process flows as the basis for test scripts is the best method for insuring a comprehensive test.

• Documenting gaps and locking down the design now will save you from scrambling at go-live

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When To-be processes are confirmed, it’s time to start configuring the system

• GL is setup first, then GEMMS can proceed. • There are only a few data dependencies from

Financials– Customers entered prior to Pricing– Vendors entered prior to Contracts

• The Item Master may be modified if no transactions have yet to occur. Make sure it is correct before on-hand balances are created.

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You should understand the integration between OPM and ORAFIN

• There are four types of Integration between OPM and Financials– Master File Synchronization– Functional– Drill Down– On Line

Nearly one-third of the integration points were upgraded inOPM release 4.1 integrated with Financials 10.7

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Master Files are synched through triggers and a data synchronization utilityIntegration Method UsedAP FOB Codes C, PL/SQLAP Terms Codes C, PL/SQLSalesReps C, PL/SQLCurrency Codes C, PL/SQLExchange Rate Types C, PL/SQLExchange Rates C, PL/SQLCustomers C, PL/SQLCustomer Association C, PL/SQLVendors C, PL/SQLVendor Association ViewShipper Association PL/SQL TriggerWarehouse PL/SQL TriggerBuyers PL/SQL TriggerShipper Codes ViewFreight Bill Method PL/SQL TriggerItems PL/SQL TriggerUOM PL/SQL TriggerUOM Types PL/SQL Trigger

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Functional Integration is achieved through various OPM utilities

Integration Method UsedAP Update JPL, PL/SQLGL Update JPL, PL/SQLAR Update C, PL/SQLInvoice Price C, PL/SQLCredit/Debit Memo C, PL/SQLExpense Allocation C, PL/SQL

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Drill Downs have been a great selling point of OPM for years.

Integration Method UsedAP Payment History JPL, PL/SQLAR Invoice History JPL, PL/SQLOF GL Drill Down Oracle Forms, ViewOF AR Drill Down Oracle Forms, View

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On Line Integration allows easy access to information

Integration Method UsedAccount & Accounting UnitValidation/Lookup

JPL, PL/SQL

Credit Check JPL, PL/SQLChart of Account JPL, PL/SQLFiscal Year & PeriodValidation/Lookup

JPL, PL/SQL

Fiscal Policy Setup JPL, PL/SQLSingle Logon JPL, Oracle Forms

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OPM has no open interfaces for auto-data conversion.

• Programs have been written in the field to import item master, formula master, pricing and various other tables.

• Six API’s exist in Process Operations Control to link DCS and PLC devices

• The GEMMS Technical Reference Manual is your best friend for these activities.

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After the production system is fully loaded, a stress test should be performed

• All major business processes should be tested– Purchase to Pay

– Order to Cash

– Make to Demand

– Financial Close and Reporting

• Each module should be unit tested• The entire system should be tested to simulate

concurrent usage• All background processes should be tested - MRP,

Cost Update, Data Synch, Test Subledger

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It’s time to begin the system cutover

• End-User Training is best conducted by the client project team member with superuser assistance.

• Make sure the trainers have taken a course on ‘How Adults Learn’.

• I have had success with Big Bang and the staged implementation approach

• One of the biggest tasks is the dynamic data conversion for items/lots/locations

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Here’s where OPM is headed in the next year

• Available First Half of 1999• Integrated to Oracle Financials R11.0• Unified Administration, Oracle

Applications “Look and Feel”• Integrated to Oracle Purchasing R11.0• New version of Regulatory Management• New Discoverer 3.0 based Cost Analysis

tool

Release 11.0 Overview

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Release 11.0 Technical Summary

• Using Developer 2000 tool set• Full AOL compliance• Discoverer 3.1 • Oracle 8 Database support• Oracle Web Forms + NCA = WAN Performance

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11.0 “Look and Feel” Enhancements

• Integrated menu displays– Mixed OPM and Financial menus– Single source for transactions

• Improved data search capabilities– Data query capabilities, view next / previous record

• Flex fields replacing user class fields

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Migration Approach

Enterprise Data Model

JAM JPL (4GL)

JAM Forms/ Reports

Forms 4.5Reports 2

PL/SQL

JAM Version Developer 2000 / AOL

C APIs


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New Purchasing Features, 11.0

• Requisitions– User entered purchase requisitions– Expense or Inventory items– Workflow based approval

• RFQ’s & Quotations• MRO Purchasing• Integration with MRP• Pay on Receipt

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• Planned EDI Transactions with the Oracle EDI Gateway– X.12 and EDIFACT

• 850/ORDERS outbound P.O.• 860/ORDCHG outbound P.O. change• 832/PRICAT inbound price catalog• 843/QUOTES inbound quotes• 856/DESADV inbound ship notice• 857 inbound ship/billing notice• 824/APERAK outbound application advice

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• Oracle Self-Service Web Applications– Web Employees (for requisitioning)

• Create/view reqs with a browser

– Web Suppliers• Supplier access through a browser

– View invoices, payments, P.O.’s, past due receipts, etc.

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Summary of Oracle Process Manufacturing

• Strategy: focus on process industries

• Release 4.1 – Began shipping September ‘97– Continue to improve quality, customer satisfaction

• Release 11.0 – Convert to Developer/2000– Integrate Oracle Purchasing

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