Oracle Work in Process Serial Genealogy

An Oracle White Paper February 2004

Oracle Work in Process Serial Genealogy

Table of Contents
OVERVIEW............................................................................................................... 1 SETUP....................................................................................................................... 2 PREREQUISITES ................................................................................................. 2 TEST CASE .............................................................................................................. 4 DEFINE ITEMS .................................................................................................... 4 BOM & ROUTING DETAILS.............................................................................. 5 GENERATE SERIAL NUMBERS ....................................................................... 6 RECEIVE SERIALIZED COMPONENTS........................................................... 8 CREATE DISCRETE JOB............................................................................. 10,18 WIP MOVE TRANSACTIONS ..................................................................... 11,19 COMPLETION TRANSACTIONS ............................................................... 15,21 MATERIAL TRANSACTIONS.......................................................................... 19 VIEW SERIAL GENEALOGY........................................................................... 25 KNOWN ISSUES ................................................................................................... 30

Oracle Work in Process Serial Genealogy

OVERVIEW

The intention of this document is to provide an insight and high-level overview into Serial Genealogy feature provided in Oracle Applications. It also covers the much needed setup points. Serial Genealogy is a feature first delivered with 11.5.2 version of the Oracle Applications. It tracks the transaction and multi-level composition history of any serial controlled item from receipt, through work in process and inventory to the customer sale. The composition genealogy is captured through the material transactions screen in Oracle Work in Process. The graphical genealogy display provides an easy way for users to trace serialized item activities. Users may trace from an assembly down through all of its components or may trace from the component to the finished good. Serial Genealogy provides a tracking method to enable the tracking of the serialized items through the life cycle of a product. This genealogy tracing enables the users to expedite problem isolation and improve response to customer request. It also helps to track and regulate supplier performance and quality.

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SETUP

Following are the prerequisites to record the issue of serialized components to serial controlled assemblies:
PREREQUISITES

Any assembly or sub-assembly which is to be included in the genealogy must be set up as: Serial Control - Predefined (Item Master/ Organization Item Setup)

Navigation: Responsibility: Inventory Items/Master Items OR Items/Organization Items

The serial numbers for the assembly (referred to in 1) must be generated before creating the WIP jobs to build the assemblies.

Navigation: Responsibility: Inventory On-hand, Availability/Generate Serial Numbers OR Reports/ Items/Serial Generation

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3 Serialized components must be set up as: Serial Control - At Receipt or Predefined (Item Master/ Organization Item Setup).

Serialized components must have been received into inventory before they can be issued to the assembly job

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TEST CASE: DEFINE ITEMS Navigation: Responsibility: Inventory Items/ Master Items

Apply and Done

NOTE: Top level of assemblies and subassemblies need to have Serial Control set to Predefined. Referring to the BOM structure below, for FALH001 and HD00001, Serial Generation should be set to Predefined. We can use Subassembly template while creating HD00001. Serial generation for the subassembly HD00001 is also set to Predefined with Starting Prefix as RX and Starting Number is 100.

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In this demo, we have used the attribute control of serial number at Master level. You can refer to page 5-36 of Oracle Inventory Users Guide For differences between the predefined and other settings. Assign the item to Inventory Organization, M1 Seattle Manufacturing

Similarly create the serialized components by copying it from a Purchased item and assign it to Inventory Organization M1 Seattle Manufacturing. Please note the components (KN00001, AKLH001, BC00001, H000001 and D000001) should be Serial Controlled, either At Receipt or Predefined.
BOM & ROUTING DETAILS

BOM Details:

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FALH001 - Front Axle (LH) Components & its Description KN00001 Knuckle AKLH001- Arm Knuckle (LH) HD00001 Hub & Disc Assembly BC00001 Brake caliper HD00001 Hub & Disc Assembly Components & its Description H000001 Hub D000001 Disc Quantity 1 2 Supply Type Operation Pull @ Op. 10 Assembly Pull Quantity 1 1 1 1 Supply Type Assembly Pull Assembly Pull Assembly Pull Push

Routing Details:
HD00001

FALH001

GENERATE SERIAL NUMBERS

Generate Serial Numbers for Predefined Serial controlled items. (FALH001 and HD00001).
Navigation: Responsibility: Inventory On-hand, Availability/Generate Serial Numbers OR Reports/Items Select Single Request, click OK Chose Serial Generation from the list of values

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Select the parameters and Submit the request. Note the Request ID.

Ensure the request completes normal. The output of successfully completed Serial Generation request will be similar to the one below:
___________________________
Retrieving auto-load serial values Starting serial number prefix: CD; starting serial number 1401 Process completed -- 100 rows updated ____________________________

If the process errors out, review the log file and query Metalink for the resolution. Repeat the same steps for generating 100 serial numbers for the Subassembly HD00001 (RX100 to RX199)

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RECEIVE SERIALIZED COMPONENTS

Raise a Purchase Order for all the components (AKLH001, KN00001, BC00001, H000001 and D000001) and receive them into Subinventory (Stores)
Navigation: Responsibility: Purchasing Purchase Orders/ Purchase Order

Submit the PO for Approval and get it Approved. To receive these items,
Navigation: Responsibility: Purchasing Receiving/ Receipts

Query for the Purchase Order 3483 Select the line

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Click on Lot-Serial button

Enter the Start Serial Number and tab out to get the End Serial Number. Click Done to proceed to the next line.

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Receive the rest of the serialized purchased items BC00001 (serial numbers 5801 5900), H000001 (serial numbers 401 500), D000001 (serial numbers 4301 4500) and KN00001 (serial numbers 1001 - 1100) into the Inventory. Note the Receipt number (5125).
CREATE DISCRETE JOB

Create a Discrete job for subassembly HD00001. Qty=2; Release it.

Navigation: Responsibility: Work in Process Discrete/ Discrete Jobs

Refer to page 3 70 in Oracle Work in Process Users Guide for defining discrete jobs manually.

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In order to issue components to the job, the job must be in either released or complete status.
WIP MOVE TRANSACTIONS

If the WIP Transaction Processing profiles are set to Background, to issue serialized components to the assembly serial number, it is necessary to perform WIP Material Transaction - Specific Component checked.

If the WIP Transaction Processing profiles are set to On-line, the system prompts the user to enter the serial number of the Operation Pull and Assembly Pull components issued to the assembly when performing WIP Move and Completion Transactions respectively.

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In this test case, the following WIP and INV Transaction Processing (TP) profile options are set to 'Online Processing' to prompt the users to enter the serial number of the components issued and to update the Inventory on-line. TP:WIP Move Transaction TP:WIP Operation Backflush Setup TP:WIP Completion Transaction Form TP:WIP Completion Material Processing TP:INV Transaction Processing Mode
Navigation: Responsibility: Work in Process Move Transactions/ Move Transactions

Move the entire quantity (2 No.s) from 10Que to 20Que

Click Save, it prompts you to enter the serial number of the Operation pull component (H000001) being issued to the job 47533.

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Enter the quantity issued and Click Lot/ Serial. Choose the serial number being issued from the list of values as shown below. Also enter the assembly serial number which is receiving the serialized component This will link the component serial to the assembly serial for the genealogy tree.

Click Done. This brings you back to the Backflush screen.

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Click Done to save the Move transaction. Move the job through all the operations till it reaches the To Move intra operation of the last operation defined on its routing.

Save this Move Transaction.

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COMPLETION TRANSACTIONS Navigation: Responsibility: Work in Process Material Transactions/ Completion Transactions

Enter the Job name, tab out and Click Continue

Enter the Completion Subinventory and the quantity Click on Lot/Serial

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Select the Start Serial Number and tab out to get the End serial Number populated. Click Done.

Done Backflush screen pops up prompting the user to enter the serial number of the Assembly pull component/s.

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Click Lot / Serial

Choose the serial number being issued from the list of values. Also enter the assembly serial number that is receiving the serialized component.

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Click Done to save the Completion Transaction. Please note that since assembly HD00001 is under serial number control, no completions are allowed from Move Transactions form.
CREATE DISCRETE JOB Navigation: Responsibility: Work in Process Discrete/ Discrete Jobs

Now, create a Discrete job for the final Assembly; Release it.

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WIP MOVE TRANSACTIONS

Perform Move transactions until the assembly is moved to the ToMove intra-operation of the last operation in the routing.

Save it.
MATERIAL TRANSACTIONS

To issue serialized Push components to the assembly serial number: Perform WIP Material Transaction
Navigation: Responsibility: Work in Process WIP Material Transactions/Material Transactions

Continue

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Click Lot / Serial

After choosing the serial number of the components being issued from the list of values. Chose the assembly serial number that is receiving the serialized component. This will link the component serial to the assembly serial in the genealogy tree. Done

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COMPLETION TRANSACTIONS Navigation: Responsibility: Work in Process Material Transactions/ Material Transactions

Click Continue

Click Lot/ Serial

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And choose the serial number of the final assembly being built. Click Done Enter the Serial numbers of the Assembly Pull components for the job

For each of the components, enter the serial number/s being issued. Also enter the assembly serial number that is receiving the serialized component(s).

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Done

Done

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Done

Click Done to save the Completion transaction. The Discrete job 47537 is completed now.

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VIEW SERIAL GENEALOGY

To view the Serial Genealogy of the final assembly built,

Navigation: Responsibility: Inventory On-Hand, Availability/Serial numbers

Query for the Serial Number CD1402 for the assembly FALH001

Find

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Click View Genealogy

Expand all the nodes by clicking on each of them (+)

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The graphical display enables one to track the genealogy (parent & child relationship) of serial controlled items. Users can easily trace from an assembly down through all of its sub assemblies and components and their Serial numbers used in building the final assembly.

After expanding all the nodes, clicking on each component shows all the transactions performed on the serialized components/Subassembly.

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Similarly you can query any component/subassembly

Navigation: Responsibility: Inventory On-Hand, Availability/ Serial numbers

Find

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Click View Genealogy.

Go to Parent Details tab. This graphical genealogy tree will trace from the component to the finished good. This powerful Serial genealogy feature facilitates the user to map out an assembly down through all its components OR trace from the component to the finished good. This helps the users to expedite problem isolation and improves response times to customer queries. Its also handy to track and regulate supplier performance and quality.

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SOME KNOWN ISSUES:

(i) Not possible to see the Serial Genealogy from WIP module. An Enhancement Request (bug 2847070) is logged for the issue. (ii) Cannot view transactions of lot and serial controlled item in serial genealogy window (bug 2265725) Apply Patch 2581344. Fix is included in 11i.INV.I (2371213) and 11i.DMF_PF.I (2697753) (iii) Serial Genealogy Gets Error: FRM-40106 No Navigable Items In Destination Block. Refer to Metalink Note: 191477.1 (iv) There is an Enhancement Request (Bug 3049062) for serial genealogy even if parent is serial controlled at receipt. (v) User encounters the following error FRM-47010:Cannot add parameter to parameter list FND_FORM_ARGS:null key specified when clicking on the onhand button when the cursor is on the node that does not have transaction details (Bug 2725936). - Apply Patch 2725936. Fix is included in 11i.INV.I (2371213) and 11i.DMF_PF.I (2697753)

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Serial Genealogy December 2003 Author: Karthikeya Subbarao Oracle Corporation World Headquarters 500 Oracle Parkway Redwood Shores, CA 94065 U.S.A. Worldwide Inquiries: Phone: +1.650.506.7000 Fax: +1.650.506.7200 www.oracle.com Oracle is a registered trademark of Oracle Corporation. Various product and service names referenced herein may be trademarks of Oracle Corporation. All other product and service names mentioned may be trademarks of their respective owners. Copyright 2003 Oracle Corporation All rights reserved.