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Oracle Process Manufacturing - Implementation Questionnaire

Inventory
How many different products within the product line?
Total how many ingredients and byproduct items present within the product line?
Are there any intermediate items which are stocked in inventory?
What are the main inventory keeping locations within the manufacturing plant
Are Finished Goods Lot and Grade controlled?
Are Raw Materials Lot and Grade controlled?
What are the main unit of measures used?
Is the stock tracking done in multiple units for the same item?
Are different pack-sized Finish Products treated as different Items / SKUs?
Is the shelf life maintained for different ingredients / products ?
FG Storage happens in same warehouse or different?
Reusable waste Storage locations?
Are the Co-products produced during batch processing?
Whether Items have Version control?
Lot numbering/sequencing?
How are packaging materials defined in inventory - Diff. item codes for diff type of containers /
packaging?
On what basis the material is moved from main storage to production floor?

Product Development
Do multiple formulas / recipes exist for one product?
Version control for formulas, recipes and routings?
Codification logic for formulas, recipes ?


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How frequently does the formula / recipe change ?
Process loss information available in formulas?
Are scrap / waste items defined and used in formulas?
Creation and Approval process of Recipe/Formula?
How packaging waste is handled?
Is there any tracking of technical parameters / process parameters like moisture content etc.in
formulas / recipes?
Are formula / recipes maintained in baan system ? Availability of data?
Is the resource (equipment/man-power etc.) tracked in the system ; data availability?
Are routings (operation steps) maintained in the system; availability of data?
Are the packing materials defined as a part of formula?

Process Execution
What % of production is MTO?
What is the basis for daily production - Manual / System generated production schedule ?
How many batches are processed within a day?
Finished Good is produced through a single batch or a series of batches for different
intermediates?
What arte the intermediates which are stocked in inventory?
Is there any sub-contracting process involved?
How is production data captured presently? -- Through system driven batch execution or
manually in excel sheets?
How frequently production data is captured?
What all information is captured for production?


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What is the general range of batch size?
How is scrap generation and rejection process handled?
How is rework process handled?
How many shifts of production? Is there 24 Hr operation?
Are the production batches linked to sales orders in "Make To Order" scenario
Automatic numbering of batches?
How is process loss tracked?
Any inventory keeping locations within the production line or continuous process?
How is variance tracking (between planned and actual usage - material / resources) done for
production batches?
What are the interaction points of production department with other departments?
What all PLC / equipments linked to prouction system?
What is the WIP reconciliation process followed at period ends?

Quality Control
What are the different stages of quality inspection?
How is the quality inspection data recorded - Manual or system ?
Is the material tagged with quality grades after quality inspection?
How is rejected item treated, what is the process followed for the same?
Item / Vendor / Customer quality specifications maintained in the system ?
Is quality inspection done on the basis of sampling plans?
Criteria for defining inspection samples and conducting quality checks?
Material expiry and shelf life tracking ?
Quality department structure?
How is communication managed between quality and other departments?
Any approval methodology followed within QC ?


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Costing
Costing method for raw materials?
Costing method for Finished goods?
How is resource cost (equipment, man-power) tracked? Is it a part of FG direct cost?
How is overhead cost managed ? Tracked at an aggregate level or product level?
Present accounting process for production related transactions?

Reporting requirements