BILL OF MATERIAL (1).pdf

Oracle

Applications 11i

Bill of Materials

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Introduction

Overview of Bill of Material

Oracle Manufacturing and Oracle Order

Management use bills of material to store lists

of items that are associated with a parent item

and information about how each item is

related to its parent.

Oracle Manufacturing supports standard,

model, option class, and planning bills of

material.

Can create either an engineering or

manufacturing bill, copy an existing bill, or

reference a common bill.




Bill of Material

BOM Item

Sub Assembly1 Phantom Sub

Assembly

Component1 Component2

Sub-

Component1

Sub-

Component …

Sub-

Component1

Sub-

Component …




Product integration

Oracle Bills of Material integrates with the

following applications

Oracle Inventory

Oracle Engineering

Oracle Work in Process

Oracle Purchasing

Oracle Master Scheduling/MRP and Oracle

Supply

Chain Planning

Oracle Order Entry

Oracle Cost Management




Bill of Material Types

Standard

Model

Option Class

Planning

Engineering

Phantom




Bill of Material Types (Contd.)

Standard : A standard bill of material is the most

common type of bill and lists the mandatory

components, the required quantity of each

component, and information to control work in

process, material planning, and other Oracle

Manufacturing functions.

Model : A model bill of material defines the list of

options and option classes you can choose in

Oracle Order Management to order a

configuration.

Planning : A planning bill of material is a bill of

material structure that includes a percentage

distribution for its components. The percentages




Navigation Bill of materials

Bill of materials

Bills

Bills




Main page C

om

ponents

Various tabs available

Choose buttons to perform related tasks:

Substitutes :- Assign substitute components

Designators :- Create reference designators

Bill Details :- Reference common bills

Revision :- Define item revisions

BOM Item




Components

Bills of Material restricts the types of items

you can assign as components based on the

type of bill you are defining.

Valid Parent/Component Relationships

Parent BOM Item

Type

Component BOM

Item Type

Standard Item Standard Item

Model Item Standard Item,

Model Item,

Option Class Item

Option Class Item Standard Item,

Model Item,

Option Class Item




Revisions

Can define any number of revisions for

the item

Revisions are sorted according to

ASCII rules. Therefore, cannot use

revision 10 after revision 9 because,

according to ASCII sorting, 10 precedes

9.




Revisions (Contd.)

List all the Revisions for BOM Item.




Substitute Component

Substitute Component. E.g. A 40GB HDD can be

substituted by a 60 GB HDD




Reference Designators

Reference designators are sequenced

comments and instructions that pertain to a

component.

The warning indicates that the reference

designators cannot exceed the component

quantity. If qty related check box is

unchecked then the designators can

exceed component quantity.




Alternate Bills

Alternate field is used

to create alternate bills




Copying Bill Information

You can save time defining new, similar

bills by copying their information rather

than creating them manually.

You can copy a bill from your current

organization or from another

organization that shares your same

item master organization.

You can then modify your new bill as

necessary.

You can copy any revision of a primary

or alternate bill.





(Contd.)

Tools Copy Bill

from. To copy from

existing bill





(Contd.)

Organization where

bill exists

Select Item whose bill is to

be copied





(Contd.)

The following message

is displayed when copy

button is pressed.





(Contd.)

The components, substitutes, designators etc are

copied for this bill.




Common Bills of Material

If two or more organizations

manufacture the same item using the

same bill of material, you can define the

bill in one organization and reference it

from the other organizations.

You cannot reference another bill or

routing as a common if that bill or

routing also references a common. In

other words, you cannot create a chain

of common references.

You can only reference another bill or





(Contd.) Tools Create

common bills





(Contd.) Single Organization: Enter the organization and item names where the common bill

needs to be created.

Organization Hierarchy: Enter the required name of the organization hierarchy. In

this case, the processing is done for all organizations below the current

organization in the chosen organization hierarchy.

All Organizations: Then processing is done for all organizations that have the same

item master organization as the current organization.





(Contd.)

When clicked on OK a

request is submitted.

The status of common

BOM creation can be

seen from view log of

concurrent request.




Practice

Create a BOM. Add components and other

necessary details for BOM. Create

Substitute components and Reference

Designators.

Create a new BOM by copying an existing

BOM

Create an alternate BOM for an item in an

organization.

Enable an item in a second organization

and copy a BOM from the first

organization.




Routings




Introduction

A routing defines the step–by–step

operations you perform to manufacture

a product.

Each routing can have any number of

operations.

For each operation specify a

department that determines the

resources you may use for that

operation.

Routings are used to specify the

processes that are used to manufacture




Primary and Alternate Routings

A primary routing is the list of

operations most frequently performed

to build a product.

When you define a new primary

routing, you specify only the item (no

alternate name) and you can assign a

routing revision.

You can define one primary routing and

many alternate routings for an item.

You can define an alternate routing to

describe a different manufacturing




Dynamic Routing

Paths that jobs take are not always

known at creation. Depending on initial

operations and their results, operation

flexibility is frequently required.

There can be numerous possibilities

defined as part of a routing network,

any one of them being selectable based

on the outcome of the last operation,

E.g. A Chemical product that undergoes

some chemical reaction.




Creating a Routing

For each routing, define the operations,

the sequence to perform them, and the

resources required at each operation.

You can define either a primary or an

alternate routing

You must define at least one

department before you can create a

routing

BOM Allowed must be set to Yes for the

item you are creating a routing

You assign department resources to an




Overview (Contd.)

Resources are anything— except

component material used to

manufacture, cost, or schedule

products.

A department is a collection of

resources designed to perform certain

tasks.

A department class is a collection of

departments.




Overview (Contd.)

Department Class - Production

Department: Machining Department: Welding

Shift 1 Machinist

Drill

Press

Welding

Torch

Welder

Shift 2

Shift 1

Shift 2

Shift 1

Shift 1

Resources

Department

Department

Class




Creating a Department Class

Department classes are used to group departments for shop floor scheduling

and control, and to identify manufacturing cells and flexible machine

centers. Department classes are used for reporting purposes.

Navigation

Setup

Department

Classes

Departments button

display the departments

assigned to this

department class and the

dates when these

departments can no

longer be assigned to

routing operations.




Defining a Department

A department is an area within your

organization that consists of one or

more people, machines, or suppliers,

where you want to collect costs, apply

overhead, and compare load to

capacity.

You assign a department to each

operation in a routing, and assign

resources that are available for that

department.

Navigation




Defining a Department (Contd.)




Defining a Department (Contd.)

Click Resources button on the Departments page

Each resource can be

assigned to any

number of

departments;

multiple resources can

be assigned to each

department.

For owned resources, indicate

whether this department can

share

the resource and capacity with

other departments.

Enter the number of capacity units

(resource units) available for

this department, for example, the number

of machines for a

machine resource.




Defining a Resource

Use resources to define the time an

assembly spends at an operation and

the cost you incur at the operation.

A resource is anything you require to

perform, schedule, or cost, including

but not limited to employees,

machines, outside processing services,

and physical space.

A resource and usage rate for all

scheduled activities is required in a

routing.




Defining a Resource (Contd.)

Bills of Material Routings Define Resources




Defining a Resource (Contd.)

Click on the Employees Button in Resources window

You can define the roles which represent what an employee can do

for a required task.




Creating a Routing

Bills of material

Routings

Routings




Creating a Routing (Contd.)

Item for which routing is to

be created

Organization

code

Populate for

alternate

routing

Department

name

Operation

sequence

number




Assigning Operation Resources

Resource

name

Item: When charges fluctuate with

quantity change.

Lot : When resource usage quantity

is the amount required per job or

schedule





(Contd.)

Two or more resources can be scheduled to be

working concurrently within the same job operation





(Contd.)

Determine how each resource

is charged in Work in Process.

You can charge resources

manually or automatically





- Alternate

Optionally, you can define substitute resources for each primary

resource group defined. This enables you to specify resource

sequences that can replace the primary resource group




Creating Routing Revision

The implementation date, which is either the date the revision

was added or the date the routing was transferred from Oracle

Engineering, is displayed. If the routing is transferred from

Engineering, the ECO text is displayed




Routing Details

Completion Subinventory and Locator can be entered here.




Creating Custom Deletion

Constraints

Use custom deletion constraints to enforce specific business rules.

Custom deletion constraints prevent the deletion of bills or routings if

your data meets the conditions set forth in the constraint.

Navigation

Bill of Materials

Setup

Delete Constraint




Lead Time




Lead Time Definitions

Fixed LeadTime

Fixed Leadtime is the portion of leadtime that

is independent of order quantity. This could

be setups, teardown, batch processes or

anything else that requires time to do a lot.

Fixed leadtimes for an item can be entered

manually.

A manually entered leadtime will be replaced

by the leadtimes generated by the

Manufacturing Leadtime rollup

Variable LeadTime

VARIABLE LEADTIME is the portion of




Lead Time Definitions (Contd.)

PRE-PROCESSING LEADTIME

Pre-Processing Leadtime is the time required

to release a purchase order.

It is used for Purchase orders, discrete jobs

and repetitive lines.

It can include the requisition processing and

any approval cycles required.

It can also be used for the time necessary to

create internal paperwork for a discrete job or

repetitive line from the time you learn of the

requirement.

PROCESSING LEADTIME




Lead Time Definitions (Contd.)

CUMULATIVE MANUFACTURING

LEADTIME

Cumulative Manufacturing Leadtime is the

time required to make an assembly if all raw

materials are in stock.

This assumes that you must manufacture

every assembly, level by level. BOM

automatically calculates this value.

CUMULATIVE TOTAL LEADTIME

CUMULATIVE TOTAL LEADTIME is the time

required to make an assembly if no raw

materials are in stock.




LeadTime Definitions (Contd.)

Inventory

Item

Organization Item




Cost Rollup




This-Level and Previous-Level

Costing Oracle Cost Management (OCM) uses this-

level and previous-level costing concepts.

This-level costs are the routing costs of

the assembly.

Previous-level costs are the component

costs of the assembly, including the

routing costs of those components

Previous-level costs =

Component costs

This-level costs =

Routing costs




This-Level and Previous-Level

Costing (Contd.)

This-Level Costs

The outside processing, resource, and

overhead costs at the current level of an

assembly

Any material overheads earned upon

completion of an assembly

Previous-Level Costs

The material, material overhead, outside

processing, resource, and overhead costs of

the components used in the manufacture of

an assembly




Single-Level Versus Full Cost

Rollup Item: Bicycle Single-level rollup: 110.00 Full cost rollup: 120.00

Item: Frame assembly QPA: 1 Cost: 80.00 Full cost rollup: 90.00

Item: Wheel QPA: 2 Cost: 10.00 (old) Cost: 15.00 (new)

Item: Handlebar QPA: 1 Cost: 20.00 (old) Cost: 30.00 (new)

Item: Frame QPA: 1 Cost: 50.00

Item: Seat QPA: 1 Cost: 10.00





Rollup (Contd.) Full Cost Rollup

A full cost rollup first performs a bill of material

explosion for the assemblies to determine the

structure to the lowest level. It then builds the

cost of the assemblies starting with the lowest

level and works up the structure to the top-

level assembly.

This method gives you the most current costs

for your assemblies because it reflects the

most current bill of material structure and

component costs for your assemblies.

You cannot rollup costs in the frozen or





Rollup (Contd.) Single-Level Cost Rollup

Use a single-level rollup to avoid rolling up

costs at lower levels. A single-level rollup

looks only at the first level of the bill structure

of each assembly being rolled and then rolls

the cost for the items at this-level into the

parent.

This method does not reflect structure or cost

changes that have occurred at levels below

the first level of your assemblies.

Use single-level rollups to assign costs to new

assemblies when you do not want to roll up




BOM and Routing Open Interface

- Bill of Materials




Interface Tables

BOM_BILL_OF_MTLS_INTERFACE

BOM_INVENTORY_COMPS_INTERFAC

E

BOM_ASSY_COMMENTS_INTERFACE

BOM_REF_DESGS_INTERFACE

BOM_SUB_COMPS_INTERFACE

MTL_ITEM_REVISIONS_INTERFACE




Interface Tables (Contd.)

In order to import a BOM with

components, you need to populate:


BOM_INVENTORY_COMPS_INTERFACE

If you want to assign standard comments,

reference designators, and substitute

components to your BOM, you need to

populate:


BOM_REF_DESGS_INTERFACE

BOM_SUB_COMPS_INTERFACE




BOM_BILL_OF_MTLS_INTERF

ACE table REQUIRED COLUMNS FOR

BOM_BILL_OF_MTLS_INTERFACE.

ASSEMBLY_ITEM_ID

ORGANIZATION_ID

ASSEMBLY_TYPE




BOM_BILL_OF_MTLS_INTERFAC

E table (Contd.)

REQUIRED COLUMNS FOR


ASSEMBLY_ITEM_ID

ORGANIZATION_ID

ASSEMBLY_TYPE

PROCESS_FLAG

If you create an alternate BOM, you must

also enter a value in the

ALTERNATE_BOM_DESIGNATOR

column.

If the BOM you import references a




BOM_INVENTORY_COMPS_INTE

RFACE table

REQUIRED COLUMNS FOR

BOM_INVENTORY_COMPS_INTERFAC

E TABLE

PROCESS_FLAG

COMPONENT_ITEM_ID

COMPONENT_SEQUENCE_ID

OPERATION_SEQ_NUM

EFFECTIVITY_DATE

BILL_SEQUENCE_ID

You must also specify a value in the

ALTERNATE_BOM_DESIGNATOR




BOM_ASSY_COMMENTS_INTER

FACE table

REQUIRED COLUMNS FOR THE


TABLE.

STANDARD_REMARKS_DESIGNATOR

BILL_SEQUENCE_ID

PROCESS_FLAG




BOM_REF_DESGS_INTERFA

CE table REQUIRED COLUMNS FOR

BOM_REF_DESGS_INTERFACE TABLE.

COMPONENT_REFERENCE_DESIGNATOR


PROCESS_FLAG

You can only import data into the

BOM_REF_DESGS_INTERFACE table

for standard components assigned to

standard, model and option class BOMs.




BOM_SUBS_COMPS_INTERF

ACE table REQUIRED COLUMNS FOR

BOM_SUBS_COMPS_INTERFACE

TABLE.

SUBSTITUTE_COMPONENT_ID

SUBSTITUTE_ITEM_QUANTITY


PROCESS_FLAG

You can only import data into the

BOM_SUBS_COMPS_INTERFACE table

for standard components assigned to

standard, model and option class BOMs.




Import Rules

Different values of PROCESS_FLAG are

All inserted rows must have the PROCESS_FLAG set to 1 (Pending)

Import program validates records with PROCESS_FLAG 1. If the assign or validate procedure fails for a row, the program sets the PROCESS_FLAG to 3 (Assign/Validation Failed)

If a row fails on import, the program assigns a value of 4 (Import Failed) to the PROCESS_FLAG

Successfully imported rows have a PROCESS_FLAG value of 7 (Import




Tracking error record

To identify the error message for a failed

row, the program automatically populates

MTL_INTERFACE_ERRORS table with

the same value as the TRANSACTION_ID

value.

Each error has a value for the

MESSAGE_NAME and REQUEST_ID

columns in the error interface table.

MESSAGE_NAME column corresponds to

messages stored in the Oracle Application

Message Dictionary.




Interface Tables for Routings

BOM_OP_ROUTINGS_INTERFACE

BOM_OP_SEQUENCES_INTERFACE

BOM_OP_RESOURCES_INTERFACE

BOM_OP_INSTRUCTIONS_INTERFACE

MTL_RTG_ITEM_INTERFACE




Interface Tables (Contd.)

To import a routing with operations and

resources, you need to populate the

following tables:




If you want to assign standard instructions

to your routings, then you populate the


table

If you enter a value in the




BOM_OP_ROUTINGS_INTERF

ACE table REQUIRED COLUMNS FOR THE


TABLE.

PROCESS_FLAG

ASSEMBLY_ITEM_ID

ORGANIZATION_ID

ROUTING_TYPE

If you are creating an alternate routing,

you must also enter a value in the

ALTERNATE_ROUTING_DESIGNATOR

column.




BOM_OP_SEQUENCES_INTE

RFACE table REQUIRED COLUMNS FOR THE


TABLE

PROCESS_FLAG

ROUTING_SEQUENCE_ID

OPERATION_SEQ_NUM

DEPARTMENT_ID

EFFECTIVITY_DATE

You must also specify a value in the


column if you assign an operation to an




BOM_OP_RESOURCES_INTE



TABLE.

PROCESS_FLAG

RESOURCE_SEQ_NUM

RESOURCE_ID

OPERATION_SEQUENCE_ID

You must specify a value in the


column if you assign resources to an

alternate routing and have not entered a




BOM_OP_INSTRUCTIONS_INTE

RFACE table

REQUIRED COLUMNS FOR THE


TABLE.

OPERATION_SEQUENCE_ID

OPERATION_DESCRIPTION_CODE

PROCESS_FLAG




MTL_RTG_ITEM_REVS_INTE


MTL_RTG_ITEM_REVS_INTERFACE

TABLE.

PROCESS_REVISION

ORGANIZATION_ID

INVENTORY_ITEM_ID

PROCESS_FLAG




Import Rules

Different values of PROCESS_FLAG are

All inserted rows must have the

PROCESS_FLAG set to 1 (Pending)

Import program validates records with

PROCESS_FLAG 1. If the assign or validate

procedure fails for a row, the program sets the

PROCESS_FLAG to 3 (Assign/Validation

Failed)

If a row fails on import, the program assigns a

value of 4 (Import Failed) to the

PROCESS_FLAG

Successfully imported rows have a




Tracking error record

To identify the error message for a failed

row, the program automatically populates

MTL_INTERFACE_ERRORS table with

the same value as the TRANSACTION_ID

value.

Each error has a value for the

MESSAGE_NAME and REQUEST_ID

columns in the error interface table.

MESSAGE_NAME column corresponds to

messages stored in the Oracle Application

Message Dictionary.







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BILL OF MATERIAL (1).pdf