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OPM R12 Exercises.

V6
Updated: 8/27/08
Page 1 of 65

The Whoopee Diet Cola Story................................................................................................7


The Recipe Diagram..........................................................................................................8

Section 1: Inventory.......................................................................................9
Exercise 1: Some Inventory Setups.......................................................................................9
1. Item Status..............................................................................................................9
2. Material Status......................................................................................................10
3. Transaction Reasons..............................................................................................11
Exercise 2: Create Items by Copy.......................................................................................12
Example 1: Create Ingredient Items...............................................................................12
Create Your First Raw Material.......................................................................................12
1.
2.
3.
4.
6.
7.

Copy Item 9802....................................................................................................12


Enter RM Item(s) Information..............................................................................12
Save.......................................................................................................................13
Assign Organizations............................................................................................13
Assign Categories.................................................................................................13
Save.......................................................................................................................14

Create Your Other Raw Materials...................................................................................14


Example 2: Create Finished Good Item.........................................................................15
Create the finished good item XXBDC01.......................................................................15
1.
2.
3.
4.
5.
6.

Copy Item 9010....................................................................................................15


Enter Item Data.....................................................................................................15
Save.......................................................................................................................16
Assign Organizations............................................................................................16
Assign Categories.................................................................................................17
Save.......................................................................................................................17

Exercise 3: Enter Item Conversions....................................................................................17


Example XXBDC01........................................................................................................18
Exercise 4: Create Beginning Inventory Balances for Raw Materials.............................19
Example 1: Create Miscellaneous Receipt.....................................................................19
Enter Miscellaneous Receipt Transaction for Sweetener..........................................19
1. Header...................................................................................................................19
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OPM R12 Exercises. V6


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2. (B) Transaction Lines...........................................................................................19


3. Enter Miscellaneous Receipt Transaction for other Raw Materials.....................20
4. Save.......................................................................................................................20
Example 2 (Optional): Create Misc. Receipt Using the Lot/Serial Button....................20
Enter Miscellaneous Receipt Transaction for Sweetener..........................................20
1. Header...................................................................................................................20
2. (B) Transaction Lines...........................................................................................20
4. [B] Done...............................................................................................................21
5. Save.......................................................................................................................21
Example 3 (Optional): Create Misc. Receipt Using Auto Generate Multiple Lots........21
Enter Miscellaneous Receipt Transaction for Sweetener..........................................21
1. Header...................................................................................................................21
2. (B) Transaction Lines...........................................................................................21
3. (B) Lot / Serial......................................................................................................21
4. (M) Actions > Generate Multiple Lots.................................................................21
4. [B] OK..................................................................................................................22
5. [B] Done...............................................................................................................22
6. Save.......................................................................................................................22

Section 2: Product Development.................................................................23


Exercise 1: View Product Development Settings................................................................23
1. Organization Parameters.......................................................................................23
2. Product Development Security Access.................................................................23
Exercise 2: Create Formula.................................................................................................23
1. Header...................................................................................................................23
2. [T] Products..........................................................................................................25
3. [T] Ingredients......................................................................................................25
4. Save.......................................................................................................................26
5. Change Status.......................................................................................................26
Exercise 3: Create Resource(s)............................................................................................26
Create the Generic Resource.....................................................................................26
Create the Plant Resource..........................................................................................27
1. Header...................................................................................................................27
2. Capacity Block......................................................................................................28
3. [B] Devices...........................................................................................................28
4. [B] Equipments.....................................................................................................28
5. [B] Instances.........................................................................................................28
6. [B] Alternates........................................................................................................28
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OPM R12 Exercises. V6


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7. [B] Process Parameters.........................................................................................29


Exercise 4: Create Operation...............................................................................................29
1. Header...................................................................................................................29
2. Activities...............................................................................................................30
3. [B] Resources........................................................................................................30
4. SAVE....................................................................................................................32
5. Change Status.......................................................................................................32
6. Complete Your Other Operations.........................................................................32
Exercise 5: Create Routing..................................................................................................32
1. Header Information...............................................................................................32
2. Routing Steps........................................................................................................34
3. SAVE....................................................................................................................34
4. Change Status.......................................................................................................34
5. Other Buttons on Routing Detail Form................................................................34
Exercise 6: Create Recipe.....................................................................................................35
Automatic Recipe Generation (SKIP).............................................................................35
Manual Recipe Generation..............................................................................................35
1.
2.
3.
4.
5.

Header...................................................................................................................36
[TAB] Plant/Laboratory........................................................................................37
SAVE....................................................................................................................37
Change Status.......................................................................................................37
Other Tab and Buttons..........................................................................................37

Exercise 7: View Master Batch Record...............................................................................38


Exercise 8: Recipe Validity Rule..........................................................................................38
[B] Validity Rules............................................................................................................38
1. Header...................................................................................................................38
2. (T) Validity Rule...................................................................................................38
3. Change Status.......................................................................................................39

Section 3: Process Execution.......................................................................40


Exercise 1: Create Batch......................................................................................................40
Example 1: Create Batch Product Output Tab............................................................40
Example 2: Create Batch Recipe Tab..........................................................................40
Example 3: Create Batch Total Input Tab...................................................................41
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OPM R12 Exercises. V6


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Example 4: Create Batch Total Output Tab.................................................................42


Exercise 2: Gantt Chart / Production Scheduler...............................................................42
1. Enter Schedulers Workbench Start Up Parameters.............................................42
2. View Gantt Chart (Schedulers Workbench)........................................................42
3. Reschedule Batch..................................................................................................43
Exercise 3: Complete Batch Using Gantt Chart Interface................................................43
Example 1: Complete Batch with Zero Variance...........................................................43
Exercise 4: Complete Batch Using the Batch Detail Form...............................................44
Example 1. Complete Batch with Product Variance and Raw Material Correction.......44
Example 2: Complete Batch with Resource Variance....................................................45

Section 4: Process Quality...........................................................................47


Exercise 1: Process Quality Parameters.............................................................................47
Exercise 2: Status Code........................................................................................................47
Exercise 3: Sample Plan.......................................................................................................48
Exercise 4: Profile Options...................................................................................................48
Exercise 5: Update Default Item Status..............................................................................49
Exercise 6: Create a New Miscellaneous Receipt...............................................................49
Exercise 7: View Quality Tests.............................................................................................49
Exercise 8: Create Quality Specification............................................................................49
1. Header....................................................................................................................50
2. [Tab] Targets.........................................................................................................51
3. Save.......................................................................................................................51
4. Change Status.......................................................................................................51
Exercise 9: Create Specification Validity Rule for Inventory...........................................52
1. [T] Inventory.........................................................................................................52
2. Save.......................................................................................................................52
3. Change Status.......................................................................................................52
Exercise 10: Manual Sample Creation & Disposition........................................................53
Exercise 11: View E-Record Details....................................................................................54
Exercise 12: Edit Your Specification Validity Rule............................................................54
Exercise 13: Mass Results Entry and Composite Results.................................................54
1. Check Profile Options...........................................................................................54
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2.
Complete a Batch for BDC01 from the Product Output Tab for 1000 LB....54
3. Find Group Samples.............................................................................................54
4. Highlight Your Sample Group..............................................................................55
5. [B] View Samples.................................................................................................55
6. Change Sample Disposition..................................................................................55
7. Mass Enter Results...............................................................................................55
8. Save.......................................................................................................................55
9. [B] Composite Results..........................................................................................55
10. [B] Create Composite..........................................................................................56
11. Disposition of Samples.......................................................................................56
Exercise 14: Create Spec Validity Rules for Customer.....................................................56
1. Query up Your Spec for XXBDC01.....................................................................56
[T] Customer..............................................................................................................56
2. Save.......................................................................................................................56
3. Change Status.......................................................................................................56
Optional Validity Rule Exercises..........................................................................................57
Exercise 15: Spec Validity Rule for Production.................................................................57
1. (T) Production.......................................................................................................57
2. Save.......................................................................................................................57
3. Change Status.......................................................................................................57
Optional Validity Rule Exercises..........................................................................................58
Exercise 16: Create Spec Validity Rules for Supplier........................................................58
1. [T] Supplier...........................................................................................................58
2. SAVE....................................................................................................................59
3. Change Status.......................................................................................................59

Section 5: Costing........................................................................................60
Exercise 1: Standard Costing...............................................................................................60
1. Enter Item Standard Cost for Sweetener (XXSW02)...........................................60
2. Enter Item Standard Cost for Other Raw Materials..............................................60
3. Enter Resource Standard Cost for Operator 2 (XX-OP02)..................................61
4. Standard Cost Rollup............................................................................................61
5. View Results.........................................................................................................61
6. View Formula Details...........................................................................................61
7. View Routing Details............................................................................................61
Exercise 2: PWAC Costing...................................................................................................62
1. Purchasing.............................................................................................................62
3. Enter Resource PWAC cost..................................................................................62
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OPM R12 Exercises. V6


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4.
5.
6.
7.

Complete A Batch.................................................................................................63
Actual Cost Process for PWAC.............................................................................63
Actual Cost Process for LAC................................................................................63
View Actual Transaction Costs.............................................................................63

Exercise 3: Lot Costs............................................................................................................64


1. Lot Cost Items.......................................................................................................64
2. Lot Cost Process...................................................................................................64
3. Button: OK...........................................................................................................64
4. Button: Submit.....................................................................................................64

Section 6: Lot Genealogy.............................................................................65


Exercise 1: Lot Genealogy....................................................................................................65
U R Done.................................................................................................................................65

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OPM R12 Exercises. V6


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The Whoopee Diet Cola Story


A recent consumer poll suggested that soft drink customers desired a diet cola that tasted
more like regular cola. In an attempt to respond to this news, Whoopee Cola, Inc
(Nasdaq WHOOPS) has embarked on a development campaign. You will act as the WCI
chief Formulator (also their only formulator), the WCI manufacturing engineer, as well as
the WCI production control manager (and any other lackey we can think of) to move the
product from R&D through its first production run of bulk product.

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The Recipe Diagram


This is how Whoopee Diet Cola is made:
Formula:

XXBDC01
Bulk Diet Cola
100 LB
XXSW02
Sweetener
19 LB

XXCE03
Cola Extract
1 LB

XXAC04
Artificial Color
5 LB

XXH2O05
Water
75 LB

Process:
Operation

Blend all
Ingredients

Fill Bulk
Container

Activity

Inspect
Extract
& Color
XX-IN
QC

Inspect
Finished
Product

C-BLEND

CAFILLING

QC

Resources

- QA
Inspector
1-QC

- Operator
- Blender
1-Labor1
1-Blender

- Operator2
- Filler
XX-Op02
1-Filler

- QA
Inspector
1-QC

1000 LB
per hour

1000 LB per
hour

500 LB per
hour

1000 LB
per hour

Run rate

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OPM R12 Exercises. V6


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For most exercises:


Log on as: process_ops / welcome
Select responsibility: OPM All
Select organization: PR1
If there are any log on exceptions, they will be noted for that exercise.

SECTION 1: INVENTORY
Exercise 1: Some Inventory Setups
1. Item Status
(N) Inventory > Setup > Items > Status Codes
Status attributes enable and disable the functionality of an item over time. Each status
attribute allows you to enable the item for a particular use. For example, if you set the
status attribute Purchasableto Yes, you can put the item on a purchase order. In ADS,
Active is the status which defaults in on new item creation.
Screen Capture #1: Item Status

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These are the status attribute definitions


Screen Capture #2: Status Attribute Definitions

2. Material Status
(N) Inventory > Setup > Transactions > Material Status
Screen Capture #3: Material Status

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OPM R12 Exercises. V6


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Material Status Terms

Allow Reservations. If you select this check box, then you can view material
associated with this status in the Item Reservations window. You can create a
reservation against the material, and the system includes it in the available to
reserve calculations.
Select Include in ATP if you want material associated with this status to be
eligible for available to promise. The system then includes material with this
material status in available to promise calculations.
Select Nettable to include material that is associated with this material status with
main planning.
Indicate whether this status is used at the subinventory, locator, lot, or serial level.
For example, if you select subinventory, the system allows you to assign the
material status at the subinventory level.
In the Allowed Transaction column, select a transaction that you want to disallow
and click the greater than button. To move a transaction from the Disallowed
Transactions column to the Allowed Transactions column, select the transaction,
and click the less than button.

3. Transaction Reasons
(N) Inventory > Setup > Transactions > Reasons
A transaction reason is a standard means of classifying or explaining the reason for a
transaction. Transaction reasons can be used in all transaction forms. You can use these
standard transaction reasons with any type of material transaction. Oracle Inventory
provides transaction reporting and inquiring capabilities by transaction reason. In
addition, transaction reasons are a way of mapping to GL accounts.
Screen Capture #4: Transaction Reasons

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OPM R12 Exercises. V6


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Exercise 2: Create Items by Copy


Creating items by copying and changing only the necessary fields is the quickest way to
create items
Example 1: Create Ingredient Items
Create Your First Raw Material
1. Copy Item 9802
[N] Inventory > Items > Master Items
[M] Tools > Copy From
Item: 9802,
Select (B) Apply
& Then (B) Done
2. Enter RM Item(s) Information
Sweetner, XXSW02 is shown in the the example below
Field Name
Field Value
Notes
Header
Item Number
XXSW02
Alpha numeric
Description
Sweetener
(T) Main
SKIP

No updates to main tab for this exerise

SKIP

Update if you need more control than the


item you are copying from

(T) Inventory

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(T) Purchasing
SKIP

Update if you are demoing purchasing &


want to change the list price and unit of
issue (both default on the PO line)

SKIP

I only update if I must show dimensions,


weight, etc in Shipping Execution

(T) Physical Attributes

(T) Process Mfg


IMPORTANT: Normally you would not update the Process Manufacturing Tab in the
Master Items. You would update the Process Manufacturing Tab in the Organizational
Items. However, this method will work for demo setup and it is faster.
Process Quality
Checked
Enabled
Process Costing
Checked
Enabled
Recipe Enabled
Checked
Process Execution Checked
Enabled
3. Save
4. Assign Organizations
To assign Organizations, select the button on the left hand side of the Master Item form as
displayed below and Check Organizations PR1 & PR2 & LA0

To return from the Organization Assignment to the Main Tab, select the button on the left
hand side of the Master Item form as displayed below.

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6. Assign Categories
[M] Tools > Categories
Field Name
Category Set
Control Level
Category

Field Value
Allocation Class
Master
AUTOFEFO

Notes

7. Save
Create Your Other Raw Materials

XXCE03, Cola Extract


XXAC04, Artificial Color
XXH2O05, Water

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Example 2: Create Finished Good Item


Create the finished good item XXBDC01
1. Copy Item 9010
[N] Inventory > Items > Master Items
[M] Tools > Copy From
Item: 9010, Select Button Done
2. Enter Item Data
Field Name
Field Value
Header
Item Number
Description
(T) Main
Primary
Secondary
Defaulting
Deviation Factor +
-

Deviation Factor -

(T) Inventory
Lot Expiration
Control
Shelf Life Days
Grade Controlled
Default Grade
Lot Status Enabled

XXBDC01
Bulk Diet Cola
LB
GL
Default
100

100

Notes
Alpha numeric

In this demo, 10lb = 1 GA (1 lb = .1 GL).


Depending on the density of the 1 lb of
BDC, the volume could be more or less
than .1 GL. Most companies want to
control how much variance is allowed and
still pass quality. That is why we use
deviation factors. Normally in a demo you
will want to pick something more realisitc.
If container contents can go to zero, then
100% makes sense. If catchweight item,
that much deviation would not make sense.
This is a catchweight item, but we will
leave at 100 anyway.

Shelf Life Days


360

This is usually an org attribute. But we are


setting at the master level to save time.

Checked
A
Checked

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Default Lot Status

Good

(T) Purchasing
SKIP

Update if you are demoing purchasing &


want to change the list price and unit of
issue (both default on the PO line)

SKIP

I only update if I must show dimensions,


weight, etc in Shipping Execution

(T) Physical Attributes

(T) Process Mfg


IMPORTANT: Normally you would not update the Process Manufacturing Tab in the
Master Items. You would update the Process Manufacturing Tab in the Organizational
Items. However, this method will work for demo setup and it is faster.
Process Quality
Checked
Enabled
Process Costing
Checked
Enabled
Recipe Enabled
Checked
Process Execution Checked
Enabled
3. Save
4. Assign Organizations
To assign Organizations, select the button on the left hand side of the Master Item form as
displayed below and Check Organizations PR1 & PR2

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To return from the Organization Assignment to the Main Tab, select the button on the left
hand side of the Master Item form as displayed below.

5. Assign Categories
[M] Tools > Categories
Field Name
Category Set
Control Level
Category

Field Value
Allocation Class
Master
AUTOFEFO

Notes

6. Save

Exercise 3: Enter Item Conversions


DUOM Items: All dual unit of measure items must have a conversion between the
primary and secondary unit of measure. Either this conversion will be a system unit of
measure conversion or it will be an item specific unit of measure conversion.
The diet bulk colas primary uom is LB and the secondary unit of measure is GL. You
must enter an item specific uom conversion. If the primary uom had been LB and the
secondary KG, you would not have needed to enter an item specific UOM conversion as
a system level conversion already exists.
Single UOM items: There is a profile option for Process Manufacturing where you set up
the yield uom. In ADS, the yield UOM is LB. That means all items must be able to be
converted back to LB.
If you setup an item, where the primary UOM is DRUM for example, you must enter an
item specific conversion between Drum and LB.
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OPM R12 Exercises. V6


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Keep in mind, that for Process Manufacturing customers, a differentiatory for us is the
ability to enter not only item specific conversions, but lot specific conversions.
Example XXBDC01
[N] Inventory > Setup > Units of Measure > Conversions
1.
2.

Select the Inter-Class Tab


Create a new record line
(Select the green plus sign in the menu bar)
3. Enter Conversion
Field Name
Item
Base Unit

Field Value
XXBDC01
GL

Conversion

10

Notes
This is the destination base unit (the
secondary uom)
At the bottom, of the form you will have
the statement (if you did it right) 1 GL =
10 LB

4. SAVE

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Exercise 4: Create Beginning Inventory Balances for Raw Materials


You will establish beginning balances in inventory organization PR1 for your raw
materials. Create two lots for each item.
XXSW02, Sweetener
XXCE03, Cola Extract
XXAC04, Artificial Color
XXH2O05, Water
[N] Inventory > Transactions > Miscellaneous Transaction
Example 1: Create Miscellaneous Receipt
Enter Miscellaneous Receipt Transaction for Sweetener
Field Name
Field Value
Notes
1. Header
Date
Defaults
Type
Miscellaneous receipt
Account
100-1120-1440-10000000
2. (B) Transaction Lines
NOTE: Enter a Transaction Line for Each of your Raw Materials. Shown for
Sweetener
Sweetener
Item
XXSW02
Example shown for sweetener.
Subinventory
CPG-RM
Locator
CPG-RM.1.
Can be changed
Lot
XX1234
Create any Lot #. Use your initials as
prefix
Expires On
Defaults in if shelf
Calculated from Item Master Setup
life controlled
UOM
Defaults in
From the item master. Can be changed
Quantity
100,000
Account
Defaults in
Defaults in if you entered at the Header
level, 100-1120-1440-1000-0000
Reason (optional)
BEG
Reason code is not required. However, it is
an option for mapping inventory
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transactions to GL accounts
Subinventory
Locator

CPG-RM
CPG-RM.1.

Can be changed

3. Enter Miscellaneous Receipt Transaction for other Raw Materials


Go to the next line on the form and enter the next raw material receipt until you have
entered a line for them all. When it makes sense, use SHIFT F5 to copy the field above
to make data entry faster.
4. Save
Example 2 (Optional): Create Misc. Receipt Using the Lot/Serial Button
[N] Inventory > Transactions > Miscellaneous Transaction
Enter Miscellaneous Receipt Transaction for Sweetener
Field Name
Field Value
Notes
1. Header
Date
Defaults
Type
Miscellaneous receipt
Account
100-1120-1440-10000000
2. (B) Transaction Lines
Item
XXSW02
Example shown for sweetener.
Subinventory
CPG-RM
Locator
CPG-RM.1.
Can be changed
Lot
BLANK
BLANK
Expires On
Defaults in if shelf
Calculated from Item Master Setup
life controlled
UOM
Defaults in
From the item master. Can be changed
Quantity
100,000
Account
Defaults in
Defaults in if you entered at the Header
level, 100-1120-1440-1000-0000
Reason (optional)
BEG
Reason code is not required. However, it is
an option for mapping inventory
transactions to GL accounts
3. (B) Lot / Serial
Lot Number

BLANK

TAB PAST field to auto generate the lot #


OR Select [B] Generate Lot

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Quantity
5000
Create Second Lot. Go to Line #2 in Lot / Serial Block
Lot Number
BLANK
TAB PAST field to auto generate the lot #
OR Select [B] Generate Lot
Quantity
5000
4. [B] Done
5. Save
Example 3 (Optional): Create Misc. Receipt Using Auto Generate Multiple Lots
[N] Inventory > Transactions > Miscellaneous Transaction
Enter Miscellaneous Receipt Transaction for Sweetener
Field Name
Field Value
Notes
1. Header
Date
Defaults
Type
Miscellaneous receipt
Account
100-1120-1440-10000000
2. (B) Transaction Lines
Item
XXSW02
Example shown for sweetener.
Subinventory
CPG-RM
Locator
CPG-RM.1.
Can be changed
Lot
BLANK
BLANK
Expires On
Defaults in if shelf
Calculated from Item Master Setup
life controlled
UOM
Defaults in
From the item master. Can be changed
Quantity
100,000
Account
Defaults in
Defaults in if you entered at the Header
level, 100-1120-1440-1000-0000
Reason (optional)
BEG
Reason code is not required. However, it is
an option for mapping inventory
transactions to GL accounts
3. (B) Lot / Serial
4. (M) Actions > Generate Multiple Lots
Number of Lots
5
Qty Per Lot
TAB PAST
If you tab past this field, it will calculate
for you. OR you can actually fill in the Qty
per lot and the number of lots will
calculate.
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Reason Code
Supplier Lot

BEG

Optional if you fill in or leave blank


Optional. Fill in if important to track that
information (pharma)

4. [B] OK
Sometime you must press more than once
The 5 lots will generate at this time
5. [B] Done
To save the changes in the Lot/Serial form
6. Save
When you are back to the Miscellaneous Receipt form, make sure you save

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SECTION 2: PRODUCT DEVELOPMENT


Exercise 1: View Product Development Settings
Responsibility: Product Development Security Manager
1. Organization Parameters
DO NOT CHANGE
[N] Organization Parameters
Query Organization Parameters for PR1
With these parameters, you can control options for Product Development Components,
such as
Default Status
Version Control
Yield UOM
Byproduct Active
Allow Zero Ingredient Quantity
2. Product Development Security Access
DO NOT CHANGE
[N] Security Control
The Product Development Security Access window enables the Product Development
Security Manager to control access to formula data. It also enables this responsibility to
assign access by individual users or responsibilities. Organizations that own formulas
must be listed on this window in order to obtain access to the formulas they own.

Exercise 2: Create Formula


Responsibility: OPM All
[N] Formulator > Formulas

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1. Header
Field Name
Formula

Field Value
<Your Formula>

Status

New (defaults in)

Version
Description

1
<Your product
description>
Blank
Blank
Defaults in
Defaults to PR1
Defaults in
Defaults to you
Defaults in
Checked by default
Not Checked

Comments
Class
Class Description
Organization
Description
Owner
Owner Description
Scaling Allowed
Packaging

Notes
For demos we usually name the formula the
same as the product it makes. This way
OPM will default in your product in the
Product field below. Ex: XXBDC01
Remember to change the formula status to
Approved for General Use after you
save.
Defaults in if Formula name and Product
mane are the same.
Optional
Used for look ups on several forms

Otherwise not scalable


For reference

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2. [T] Products
NOTE: In general, you should not create something that looks like a BOM for a demo.
The finished good quantity should ideally be a batch size. For example, the ingredients
required to make 100 LB, not 1 LB. Visit with the prospect and find out typical batch
sizes. Also, find out if the formula changes based on batch size then you can talk
about validity rules and their benefit in your demo. Occasionally a prospect will want all
their ingredients expressed as a percentage. If that is the case, make the batch size = 100
(product qty =100).
Complete Product TAB as shown in table below
Field Name
Field Value
Notes
Line
Defaults in
Defaults in
Product
<Your Product>
Defaults in if formula and product have
same name EX: XXBDC01
Description
Defaults in
Quantity
100
UOM
Defaults in
Default in to primary uom, but you can
override. Do not over ride in this exercise.
Scale Type
Proportional
Yield Type
Automatic
Cost Allocation
1
Defaults in
3. [T] Ingredients
This example is for one of your ingredients. Repeat for each ingredient using the unique
values. Review the Whoopie Cola Recipe Diagram to determine the quantity of each
ingredient needed to make 1 Bulk Diet Cola.
Field Name
Line

Field Value
1

Notes
Defaults in will increment by 1 for each
new ingredient
Your sweetener

Ingredient
XXSW02
Description
Defaults in
Quantity
19
UOM
Defaults to LB
Scale Type
Proportional
Defaults
Scale multiple
0
Only used with Integer scale type.
Scale Rounding
0
Only used with Integer scale type
Variance
Rounding
Blank
Only used with Integer scale type
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Direction
Consumption Type
Contribute to Yield
Contribute to Step
Qty
Phantom Type
Buffer
Scrap Factor
Required Quantity

Automatic
Yes
Yes

Defaults
Defaults
Defaults

Not a Phantom
Unchecked
0
Defaults

Defaults
Defaults
Used in conjunction with scrap factor to
calculate the actual amount required to
meet qty.

4. Save
5. Change Status
[M] Actions > Change Status
Field Name
Change Status To

Field Value
Notes
Approved for General There are pre-built statuses delivered to
Use
customers. But, additional statuses can be
user defined and added.

Exercise 3: Create Resource(s)


Create the Generic Resource
[N] Process Engineer > Setup > Generic Resources
Create the Generic Resource XX-Op02.
NOTE: The Resources 1-QC, 1-Labor1, 1-Blender and 1-Filler already exist in
Vision (ADS Demo Environment). You will not need to create resources.
Field Name
Resource:

Field Value
XX1-Op02

Description

Operator 2

Notes
Limit of 17 characters (alpha numberic &
special Characters)

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Usage UOM
Resource Class
Cost Component
Class

HR
(LOV)
1-LBRDIR

Capacity Area

Blank

Calculate Charges

Blank

Process Parameters Select Button to see


Button
what they look like,
but dont add

Must be HR for planning purposes


An unlimited number of cost component
classes can be set up. These can be mapped
to different GL accounts.
Usually left blank here and filled in at the
plant level
Usually left blank here and filled in at the
plant level. However, if you fill it in if
the step quantities for an operation
containing that resource exceed the
maximum capacity of a resource, the
system can calculate the correct number of
charges for the step quantity.
Usually left blank unless need to demo

Create the Plant Resource


Create your own Plant Resources for Plant PR1 using the Generic Resource you just
created above
[N] Process Engineer>Setup>Plant Resources
Check the top of the form to make sure you are in PR1
Field Name
1. Header
Resource
Resource Category

Field Value

Notes

(LOV)
Tab Past

Count
Planning Cost:

1
Fill in a value (ex:
25)
Schedule

Description defaults in
If you Tab Past, the field will fill in with
the resource name.
# of those resources
For optimized ASCP plans, OPM Resource
costing is not done here!
Used for ASCP
Not required

Schedule Indicator
Idle Time
Tolerance
SDS Window
Calendar

120

Do not know what it is, but all of the other


resources have this value

Process

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2. Capacity Block
Range
From:
To:
Ideal
UOM
Calculate Charges
Capacity Tolerance
Utilization
100
Efficiency
100
Planning
OPM-ASCP
Exception Set

See Generic Resource above

3. [B] Devices
This feature is used to define Resource Devices (OPM MES)
4. [B] Equipments
This feature associates an asset or many assets to the production equipments located in
process manufacturing organization. After establishing, you can view the resource usage
(maintenance work orders, batches, or FPOs) emanating from production, associated with
a maintainable asset. You can define your resources as assets by linking your resources
to assets defined in eAM. Linking to eAM enables OPM inventory organizations to view
the scheduled maintenance for specific resources. You create a work order by using eAM
to schedule maintenance on your resources defined as assets.
Oracle Enterprise Asset Management (eAM) is a part of Oracle E-Business Suite,
providing organizations with the tools to create and implement maintenance procedures
for both assets and rebuildable inventory items. eAM integrates with Oracle Process
Manufacturing (OPM), enabling your maintenance environment to identify eAM asset
relationships with production equipment.
5. [B] Instances
The number of resource instances is defined by the number you entered in the Count
field. If you want to link your resources to assets defined in eAM, link each resource
instance to a serial numbered asset.
6. [B] Alternates
An alternate resource is one that can perform the same operation as the primary resource.
Alternate resources are used when the selected resource cannot be used, perhaps due to
overload, breakdown, or performance issues. You can indicate resources that may be used
as alternatives to a particular resource.
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7. [B] Process Parameters


The Plant Resource Parameters window captures the process parameters (machine
settings) information specific to an inventory organization. You can enter this window
after defining the generic resource parameters. This window inherits the resources and
parameters information from the Generic Resources Parameters window and lets you
override the Target values.

Exercise 4: Create Operation


Create your own Operations, again using the XX method.
Review the Whoopie Cola Process Diagram to see the Operations.
Inspect, Extract and Color
Blend all Ingredients
Fill Bulk Container
Inspect Finished Product
The example below is for the Operation: Inspect, Extract and Color. Please create the
remaining Operations in a similar way, using the resource information on the Whoopie
Cola Process Diagram.
[N] Process Engineer > Process Operations
1. Header
Field Name
Operation:

Field Value
XX-INSP

Status:
Version:

Description
Class
Class Description
Valid From

Fill in appropriately
(LOV)
16-AUG-2007

Notes
Alpha Numeric use XX convention
Suggestion: XX-INSP, XX-BLEND, XXFILL, XX-INSPFG
Will start in New status. When you save
the operation change status to Approved
for General Use
If workflow is turned on the version
updates automatically
Not required. Class can be used

Start Date defaults however may conflict


with costing. Therefore, set to previous
period. In ADS, the easiest way is to
change the current year (2008) to the
previous year (2007)
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Valid To
Owner Org
Description
Process qty UOM

Typically you will leave blank


Defaults
of the owners org defaults in
LB

2. Activities
Enter the activities that take place in this operation. We are only adding one activity per
operation in this exercise.
Field Name
Activity

Field Value
LOV

Description
Activity Factor:

Defaults in
1

Offset Interval:

Generally leave at
default of 0

Notes
If you need to create a new activity in the
future. Process Engineer > Setup
>Activities.
EX: XX-INSP the activity could be QC
Defaults in
# of times the activity is performed in this
operation
The time delay from the start of the activity
to the point that the resource is actually req.

3. [B] Resources
After you complete the Activity Line, Select the Button: Resources
This example is for the
Operation: Inspect, Extract and Color
Activity: QC (I selected QC, you might select something else)
Review the Whoopie Cola Process Diagram to see the resources you need to add to each
Activity.
Enter Resources
Field Name
[T] Throughput
Resource

Field Value
1-QC

Notes

Which resource you choose depends on the


operation you are creating.
Description
Defaults in
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Process Qty
UOM
Usage
Usage UOM

1000
Defaults in
1
HR

[T] Cost Information


Component Class
Defaults in
Class Description
Cost analysis code

Defaults in
Defaults in

Cost analysis
Default in
description
[T] Scheduling Information
Plan type
Primary

Count

Offset Interval

Scale type

Proportional

Defaults in
Must be HR in ADS for planning to work.
The usage uom defaults in from the
resource setup.
This is the cost component class previously
assigned to this resource at setup. Can be
over written.
Defaults in
This is the cost analysis code previously
assigned to this resource at setup. Can be
over written

Select Primary to indicate that this is the


rate determining resource. Secondary to
indicate the resource that would replace the
primary when it is not available. Auxiliary
is a resource that works as a companion to
the primary and does not impact the rate of
the operation. Suggestion: In this exercise,
make the machine the primary if there are
multiple resources.
How many of these resources are we using
in this operation?
The time delay from the start of the activity
to the point that the resource is actually
required. Take the default of 0 unless you
need to demo offsets.
Fixed or proportional. Proportional as
the batch size increases, the use of the
resource increases proportionally. Fixed
no matter what the batch size, the resource
usage will stay the same. Setup is a good
example of fixed in many cases.

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4. SAVE
5. Change Status
[M] Actions > Change Status
Field Name
Change Status To

Field Value
Notes
Approved for General There are pre-built statuses delivered to
Use
customers. But, additional statuses can be
user defined and added.

6. Complete Your Other Operations


You just completed the Operation: Inspect, Extract and Color. Complete the other 3.

Exercise 5: Create Routing


Create the Routing using the XX method and your Operations
[N] Process Engineer > Process Routings
1. Header Information
Field Name
Field Value
Routing
XX<your routing>

Routing Version

Status
Routing
Description

New

Notes
Alphanumeric
Routings are re-useable. So, if only one
item runs on the routing, you might call it
XXBDC01. If multiple items run on the
routing, you might call it Beverage
Routing. If you have a high speed line and
a low speed line, you might call it Bulk
Cola Routing High Speed. In a demo, I
try to make my names for the formula,
recipe and routing easy to find. Maybe all
with the same prefix or something.
Can be setup to auto increase based on
rules. See Exercise 4.
New will default.
Enter a description

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Class

Not required for this exercise. But, the


Routing Class that is selected here, controls
the Theoretical Process Loss that defaults
in on the Routing and later, the Recipe. If
you need to add a class in the future. [N]
Process Engineer>Setup>Process Routing
Classes

Class Description
Valid From

Defaults in
16-AUG-2007

Valid To
Qty
UOM
Planned Loss

Leave blank
1000
LB
Leave blank

Theoretical
Process Loss

Leave blank

Owner
Owner
Organization

Process_ops
PR1

Date defaults in to todays date. However,


for cost rollups to work, that valid from
date must be earlier than the current period.
The current period starts Jan 1 2008
(current year). The easiest method to
ensure the date is valid for costing is to
change the year to the previous year.
Blank = never invalid
This value is expressed as a percent. For
example, a Process Loss of 1.304% would
be entered as 1.304. You will fill in when
loss is important to the demo.
If you select a Routing Class in the Routing
Header, this value defaults in from the
Routing Class Setup. You will fill in when
loss is important to the demo. Routing
Class Setup: Process Engineer > Setup >
Process Engineering Classes
Defaults in as user ID
Defaults in

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2. Routing Steps
In this exercise, there will be four routing steps (operations). Review Whoopie Cola
Process Diagram
Field Name
Field Value
Notes
Step
Usually the first line is entered as Step 10,
the second line as Step 20, the third as Step
30 and the fourth as Step 40.
Operation
LOV
Choose your first operation.
Version
Defaults in
Description
Defaults in
Step Qty
Refer to process diagram above. Match
the run rate for each Operation.
Release Type
Automatic defaults in For demos, is much easier to use
Automatic.
3. SAVE
4. Change Status
[M] Actions > Change Status
Field Name
Change Status To

Field Value
Notes
Approved for General There are pre-built statuses delivered to
Use
customers. But, additional statuses can be
user defined and added.

5. Other Buttons on Routing Detail Form


These button are not important for this exericse.

[BUTTON] Edit Step Line


Shows the fields we just talked about.
to make changes.

Once a record is saved, you must go here

[BUTTON] Step Dependencies


Defines the interrelationships between routing steps. Used to calculate planned
start times and automatic step quantity calculations.
Header all fields default in
Routing

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Routing version
Routing description
Routing step
Operation
Operation Version
Operation Description
Dependencies You will determine the previous step or steps to the one that was
highlighted (cursor was on that row) when you clicked the Step Dependencies
button.
Previous Step
Operation
Version
Dependency Type: Start to Start Finish to Start
Standard Delay
Transfer Percent:

[BUTTON] Edit Operation


We have already talked about all of these fields.
NOTE: When you select one of the lines in the activities, the buttons at the
bottom become active and you can drill down further.

Exercise 6: Create Recipe


Automatic Recipe Generation (SKIP)
It is possible for the system to automatically generate a recipe.
[N] Formulator > Setup > Recipe Generation.
The recipe will not contain a routing if it is self generated.
You set the default Recipe Status in the Organization Parameters.

Manual Recipe Generation


Create the Recipe including the Validity Rules
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[N] Formulator>Recipes

Field Name
1. Header
Recipe
Version

Field Value

Status

Defaults in as New

Description
Product

<Your Product>

QTY
UOM
Formula
Version
Creation Org
Routing
Version

Alphanumeric use the XX method


Will update automatically if workflow is
turned on
Remember to update status to Approved
for General Use after you have saved
header and detail
Complete appropriately
Or you can leave it blank and when you fill
in the formula information, the product
field will default.
Defaults in from the standard formula
amount
Defaults in

<Your Formula>
<Your Formula
version>
Defaults in
<Your Routing>
<Your Routing
Version>

Theoretical
Process Loss
Total Output Qty
UOM
Planned Process
Loss
Laboratory
Owner Org
Owner
Checkbox
Calculate Step Qty
Contiguous

Notes

Defaults in the theoretical process loss


from the Routing Class. The Routing Class
is entered on the Routing
Defaults in from the formula
Defaults in from the formula
Defaults in the planned process loss from
the routing. You can override
Your default Lab
Defaults in
Defaults in
Blank

Check if scheduling must ensure that the


batch is produced with no breaks.
Example: A 3 day batch can not be started
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Enhanced Process
Instructions

Blank

on a Friday if Saturday and Sunday are not


workdays.
Check if you are setting up MES

2. [TAB] Plant/Laboratory
If the prospect is interested in Plant or Lab specific loss, this area could be filled in to
show different loss factors for several Plants / Labs
Field Name
Organization
Organization
Name
Type:
Process Loss

Field Value
LOV

Notes
Defaults in
Plant or Laboratory
Defaults in from the header. Can override

3. SAVE
4. Change Status
[M] Actions > Change Status
Field Name
Change Status To

Field Value
Notes
Approved for General There are pre-built statuses delivered to
Use
customers. But, additional statuses can be
user defined and added.

NOTE: Keep the Recipe form open.


5. Other Tab and Buttons
These Tabs and Buttons are not important to this exercise

[TAB] Customer (SKIP)


Reference Only

[TAB] Step Quantity (SKIP)


View into the routing steps Step #, operation, version, description, charges and
qty. The qty field can be changed.

[BUTTON] Organization Details (SKIP)

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Enables you to display and, if necessary, override information defined for specific
operations and routings at the plant or laboratory level.

[BUTTON] Step/Material Association (SKIP)


Use this to associate material to certain routing steps.

Exercise 7: View Master Batch Record


From your Recipe: [M] View Master Batch Record
NOTE: Keep the Recipe form open

Exercise 8: Recipe Validity Rule


From your Recipe, select
[B] Validity Rules
Field Name
1. Header
Formula, Version
and Description
Routing, Version
and Description
Organization

Field Value

Notes

All Default from


Recipe Header
All Default from
Recipe Header
PR1

Routings are optional in OPM

Organization
Defaults
Description
2. (T) Validity Rule
Recipe Use
LOV (drop down)
Product
<Your product>
Description
Preference
Status

Defaults
1
New (defaults in)

Quantities
Standard
UOM

5000
LB

Enter the plant for which this set of validity


rules will govern

Choose Production
Usually defaults from the recipe header.
However, for co-products each product
needs its own rule
Defaults in
Change status to Approved for General
Use after you save the rule.
Used for Standard Costing

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Minimum
Maximum
Process Loss
Theoretical
Planned
Effective Dates
From

100
100,000

To

Leave blank

Defaults in
Defaults in
16-AUG-2007

Costing looks at the effective dates. The


From date needs to be prior to the start of
the current costing period. Demo Tip:
always change the year to last year.
Never expires

3. Change Status
[M] Actions > Change Status
Field Name
Change Status To

Field Value
Notes
Approved for General There are pre-built statuses delivered to
Use
customers. But, additional statuses can be
user defined and added.

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SECTION 3: PROCESS EXECUTION


Exercise 1: Create Batch
Example 1: Create Batch Product Output Tab
Schedule several batches for production as follows (record the batch number):
XXBDC01
5000 GL
Today
XXBDC01
5000 GL
Today
XXBDC01
10,000 GL
Monday of next week
[N] Production Supervisor > Batch Details
1. [B] New
2. [T] Recipe
Field Name
Product
Product Quantity
Planned Start
Planned
Completion
Required
Completion

Field Value
<Your Product>
As shown in table
above
As shown in table
above
Defaults in
Defaults in

Record Batch #:
Record Batch #:
Record Batch #:
Example 2: Create Batch Recipe Tab
NOTE: We are manually creating batches which is what I do for a demo build. In a real
setting, the customer will probably release batches from planning.
[N] Production Supervisor > Batch Details
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1. [B] New
2. [T] Recipe
Field Name
Recipe
Version
Planned Start
Planned
Completion

Required
Completion

Field Value
<Your Recipe>
<Your Version>
Will default in
Will default in

Will default in

Notes
Will default in with todays date
Will default in based on Routing or Lead
Time setup. Example: If your routing
throughput in 1000 LB / Hour and you
create a batch for 1000 LB, then the
planned completion time will be 1 hour
from the planned start time.
NOTE: You can fill in the planned
completion and the system can calculate
backwards to determine the necessary
planned start time.
When does it have to be done.

NOTE: Batch size of 100 LB comes from the formula


Record Batch #:
3. Select [B] OK
NOTE: The batch will create at the standard batch size you created on the Recipe
Validity Rule

Example 3: Create Batch Total Input Tab


The most common use for this option is in a
Push environment
Example: Todays delivery is 100,000 chickens, the manufacturer will process all
100,000. Tomorrows delivery might be 50,000 chickens. The batch size will be
scaled based on Input Quantity. The manufacturer is not pulling the raw
material based on customer demand, it is being pushed at him. Fresh vegetables
is often a push environment.
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Disassembly environment - Example: meat processors. Single ingredient input


determines batch size.
(one ingredient)
Capacity Limitation. I have a 5000 GL mixer and a 10,000 GA mixer. My total
input of all ingredients can not exceed the mixer size. Depending on which mixer
I use, I want to scale my batch size. NOTE: You can also accomplish this by
having validity rules that are capacity specific. The system will automatically
choose the right recipe for that batch size.

Example 4: Create Batch Total Output Tab

Exercise 2: Gantt Chart / Production Scheduler


Use the Gantt Chart to reschedule the start date for the second batch to Thursday of this
week. Note: The Gantt Chart displays data for one inventory organization (plant) at a
time.
[N] Production Supervisor > Production Scheduler
1. Enter Schedulers Workbench Start Up Parameters
Field Name
Field Value
Batch #
From Date
Yesterdays Date
Document
%
Documents Check
Check all
Boxes
Batch Status
Check all
Check Boxes
Resource Type
Check all
Check Boxes
Product
XX%
Your initials and wild card
Ingredient
%
Resource
%
2. View Gantt Chart (Schedulers Workbench)
Select [Button] Gantt Chart
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3. Reschedule Batch
Enable scheduling and use the Gantt Chart to reschedule the start date for the second
batch to Thursday of this week by dragging the batch to the appropriate day and
releasing.

Exercise 3: Complete Batch Using Gantt Chart Interface


Example 1: Complete Batch with Zero Variance
1. On the Gantt Chart you can right click on your batch and select details. The Batch
Detail screen will display
NOTE: I would show this method if in a demo if I had to show batch status update /
completion to prospect. OR if Im prepping the Schedulers Workbench to show a mix of
pending batches, released batches, completed batches and closed batches.
2. Run your first batch through to completion accepting all defaults and enter product
output with no variance from planned (status completed)
[M] Actions > Release. Batch Status now in WIP
[M] Actions > Complete.
3. Material Exception window will display. The product information will display in the
header. Complete the transaction information
Field Name
Transact
Transaction Type
Subinventory

Field Value
Checked
WIP Completion
LOV

Locator
Lot

%
<use the XX naming
convention>

Notes
I havent tested recently but if you
update the Organization Item with a Yield
Subinventory, this field will probably fill in
automatically.
Enter %, Tab, Select one
You can either enter a lot # on the
transaction line OR just like in Exercise 3,
you can use the lot/serial BUTTON

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Quantity

Enter appropriately. If you match the


header line quantity you will not have a
yield variance.

4. Select [BUTTON] Done. Batch Status will go to Complete. Batch Actual Quantities
on the Product Tab and Ingredient Tab will display.

Exercise 4: Complete Batch Using the Batch Detail Form


Example 1. Complete Batch with Product Variance and Raw Material Correction
[N] Production Supervisor > Batch Details
NOTE: I use this method for demo prep to complete a batch quickly to get actual costs.

1. Find your second Batch using one of the search options


2. Run your second batch to completion
The batch only yielded 4950 LB due to evaporation. Follow instructions in the
first batch exercise to change batch yield quantity.
We used a different lot of artificial sweetener than planned and used a bit less
sweetener than planned. Adjust the batch data accordingly.
For your sweetener, XXSW02
1.
2.
3.
4.

Go to the Ingredient Tab


Select Sweetener Lin
[M] Inventory > Correct Material Transactions
Verify Sweetener still selected

5. In the Transaction Line, check Correct


6. Change the Lot # (s) and Quantity. NOTE: If you used the lot field on the transaction
line, you can correct there. If you used the Lot/Serial button, you will correct there.
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7. Select [BUTTON] Correct.


When you return to the batch ingredient Tab, you will notice that the Actual field still
says the same amount. If you to go back into correct material transactions for sweetener,
you will have an exception amount.
Example 2: Complete Batch with Resource Variance
Run your third batch to completion, however, this time while all actual material amounts
are the same as the planned amounts, you used 3 extra hours of blending time because the
artificial sweetener was extra lumpy.
1.
2.
3.
4.
5.
6.
7.
8.

Select the [BUTTON] Steps


Select the Operation Blend (because that is where the resource Blender is)
Select the [BUTTON] Activities OR Drill down from the Operation Blend
Select the [BUTTON] Resources
Select the [TAB] Actual
Change the Actual Total Usage to 3 hours.
SAVE
Select the [BUTTON] Resource Transactions

You will see that the variance between planned and actual is a separate transaction that
could have a reason code associated with it.
Demo Tip: In a demo I do not show updating resource usage. I show updating material
usage if they require it. Otherwise, I enter a batch with variances and show variance
reports.
Implementation: OPM has a full set of APIs. This means that you can create your own
custom form it will populate the OPM tables correctly. Data entry is easier and quicker
because it fits the customers needs and OPM costing, variance reporting, and GL
postings will happen correctly.
General Comments:
There are zillions of scenarios in OPM Execution (Production). Your exercises in
Whoopie Cola cover just a few.
But, you have learned the most common batch exercises.
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Other things you may want to learn at a later time.


Step material association
How to revert a batch status
Incremental backflush
Quality results controlling batch progression
Individual step release
Controlling the status of one step CAN control the status of the steps after
Automatically calculating step quantities or output
Any needs that you have in the future please ask for help!! You can make Process
Execution very simple or very controlled as appropriate for the business.
Notice there are four quantity columns on Products, Ingredients and ByProducts Tabs. (it
is a folder form, so some of the fields may be hidden).
o Original Quantity. From Recipe
o Planned Quantity. Reflects material usage updates done while batch is in
Pending Status
o WIP Planned Quantity. Reflects material usage updates done while batch
is in WIP status
o Actual Quantity. Reflects material usage updates done while batch is in
Complete Status
Demo Tip: Ask prospect / customer how they calculate variance.
Variance Reporting: Depending on profile option can be the material variances can
between
Actual and Original
Actual and Planned
Actual and WIP
Actual and Actual (no variance)

Variance Accounts:

Yield Variance
Ingredient Usage Variance
Resource Usage / Efficiency Variance

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Manning Variance
Material Substitution Variance
Resource Substitution / Method Variance
Close Variance

SECTION 4: PROCESS QUALITY


Exercise 1: Process Quality Parameters
The purpose of this exercise is to view the Process Quality Parameters and discuss how to
activate different options
[N] Quality Manager > Setup > Process Quality Parameters

Exercise 2: Status Code


The purpose of this exercise is to show how to enable Change from Approved for
General Use back to New
[N] Quality Manager > Setup > Status Codes
1. Highlight Status Code 700: Approved for General Use

2. [B] Details
Enter a new Target Status of 100 as shown below if it does not already exist.

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3. Save
4. [B] OK
Note: There is a separate set of status codes for Product Development
[N] Formulator > Setup > Status Codes
The functionality works the same there.

Exercise 3: Sample Plan


The purpose of this exercise is to create a Sample Plan that will then be used in
Exercise 11
[N] Quality Manager > Setup > Sampling Plans
Sample Plans are used to generate samples automatically
Sample Plan #1
Field Name
Name
Description
Count
Quantity
UOM
Frequency
Per
UOM

Field Value
XXFour, 4 1 LB
Smpls per 1000 LB
Four, 1 LB Smpls per
1000 LB
4
1
LB
Quantity Based
1000
LB

Notes

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Exercise 4: Profile Options


[M] Edit > Preferences > Profiles

ADSP: GMD ERES MASS RESULTS ENTRY NO


ADSP: GMD ERES Batch Release No
ADSP: Inv Trans Sample Creation Yes
ADSP: Prod Tran Sample Creation Yes
ADSP: GMD ERES Sample Disposition Yes
ADSP: GMD ERES Results Entry Yes

Exercise 5: Update Default Item Status


[N] Inventory > Items > Organization Items
Query up your XXBDC01 item
[T] Inventory
In ther material Status Control Block, change the default lot status to QCCK

Exercise 6: Create a New Miscellaneous Receipt


Create a Miscellaneous Receipt for Item XXBDC01. Lot #: QCTEST. Qty: 1000
Subinventory: CPG-FGI, Locator: CPG-FGI.1..

Exercise 7: View Quality Tests


[N] Quality Manager > Setup > Tests
1. Query up Test: PR1INSECT
Record
Minimum Range: __________ Maximum Range: _________
2. Query up Test: PR1PH
Record
Minimum Range: __________ Maximum Range: _________

Exercise 8: Create Quality Specification


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Throughout the material flow WCI needs to ensure that the raw materials and products
are meeting strict quality guidelines (so where were they when we had that lumpy
sweetener?). They test outgoing Bulk Diet Cola as follows.
Table 1
Test
Insect parts
PR1INSECT
PR1PH

Target
422 parts/million

Low Acceptable
240 parts/million

Hi Acceptable
748 parts/million

6.0

4.9

7.8

(Yes, its true they reject sweetener if it doesnt have enough bug parts.)
Next, set up the Specification for the artificial sweetener
[N] Quality Manager > Specifications > Specifications
1. Header
Field Name
Spec
Version
Status
Description
Type
Overlay
Base Spec
Version
Item
Grade
Owner Org
Owner

Field Value
XXBDC01
1
Defaults New
XXBDC01
Inventory,
Item
Not checked
Blank
Blank
XXSW02
Blank
Defaults in
Defaults in

Notes
Status works the same as with all other
Status Controlled forms.
Choose from drop down list

The description will default into next field

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2. [Tab] Targets
Field Name
Field Value
Notes
Test One: Bug Parts Per Million
Seq
Defaults to 10
Will increment by 10 for each new test
Class
Blank
Test
PR1INSECT
From LOV
Method
Defaults in
Unit
Defaults in
Target
422
Minimum
240
Type over the value already in this field
Maximum
748
Same
Quantity
Blank
The amount to be drawn for a sample
UOM
Blank
Seq
Defaults to 20
Will increment by 10 for each new test
Class
Blank
Test
PR1PH
From LOV
Method
Defaults in
Unit
Defaults in
Target
6
Minimum
7.8
Type over the value already in this field
Maximum
4.9
Same
Quantity
Blank
The amount to be drawn for a sample
Test Two: Ph (PR1PH)
Go to Line Two of Targets and enter the other test, Ph
We will not be making changes to, or adding information to, the Actions, Formatting
and Planning tabs.
3. Save
4. Change Status
[M] Actions > Change Status
Field Name
Change Status To

Field Value
Notes
Approved for General There are pre-built statuses delivered to
Use
customers. But, additional statuses can be
user defined and added.

Keep Specification Form OPEN as you will be adding a Validity Rule


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Exercise 9: Create Specification Validity Rule for Inventory


The next form is a listing of all validity rules that have been set up for this specification.
Since this is your first validity rule, click the button New.
[Button] New
1. [T] Inventory
Field Name
Organization
Status
Control Block
Create Samples
Automatically
Update Inventory
Quantity
Control Lot
Attributes
Lot Optional on
Sample
In Spec
Out Spec
Sample Plan Block
Name

Field Value
PR1
Defaults to New

Notes

UnChecked

Will not create a sample automatically


without a sample plan.

Status acts the same as all status controlled


forms.

Unchecked
Checked
Unchecked
Good
Hold
Blank

NOTE: Certificates of Analysis give the quality control and identity tests for each lot. Certificates
of Compliance do not.

2. Save
3. Change Status
[M] Actions > Change Status
Field Name
Change Status To

Field Value
Notes
Approved for General There are pre-built statuses delivered to
Use
customers. But, additional statuses can be
user defined and added.
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Exercise 10: Manual Sample Creation & Disposition


[N] Quality Manager > Samples > Item Samples
1. Header
Field Name
Item
Source
SubInventory
Locator
Lot
2. [B] Get Spec
3. [T] Identity

Field Value
XXBDC01
Inventory
CPG-FG
CPG-FGI.1
QCTEST

Notes

Make sure you completed Exercise 21

4. Save
5. Label Request form will appear. Cancel unless you want to print a label.
6. [T] Results
Field Name
[T] Test OR
[T] Evalutation

Field Value
Enter Test Results in
Spec

Notes
Make sure the test results you enter are in
spec

7. Save
8. NOTICE: Each test has the In-Spec box checked and the Disposition of the Test is
now Complete
9. Change Disposition
[M] Actions > Change Disposition

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Exercise 11: View E-Record Details


[M] Actions > e-Record Details
In Exercise 4, you turned on ERES for Sample Disposition. For any record which has an
E-Record, you can view the e-Record from Actions > e-Record Details as well as in the
Evidence Store.

Exercise 12: Edit Your Specification Validity Rule


1.
2.
3.
4.

Change the Status back to New


Check, Create Samples Automatically
Add a Sample Plan: XX Qty 4 per 1000 LB
Change Status back to Approved for General Use

Exercise 13: Mass Results Entry and Composite Results


1. Check Profile Options
[M] Edit > Preferences >Profiles

ADSP: GME ERES MASS Result Entry


User Value: No
ADSP: GME ERES Batch Release
User Value: No
ADSP: ADSP InvTrans Sample Creation
User Value: Yes

2. Complete a Batch for BDC01 from the Product Output Tab for 1000 LB
See Exercise 12, Example 1 if you need a reminder of steps.
3. Find Group Samples
[N] Quality Manager > Samples > Sample Groups
On Query Screen, find sample group for your item, XXBDC01
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4. Highlight Your Sample Group


5. [B] View Samples
6. Change Sample Disposition
There should be four samples which were generated.
Change each sample disposition from Planned to Pending.
Select the Sample
[B] View Sample
Select the Disposition LOV and Select: Pending
Save
Close the sample Window to Return to Sample Summary Screen
Change the other 3 sample dispositions
Keep the Sample Summary Form Open
7. Mass Enter Results
Check the Checkbox Mass Results Entry for each of your sample lines
[B] Mass Results Entry
On the Test Entry Form, check all tests
[B] Mass Results Entry
Samples
Sample 1
Sample 2
Sample 3
Sample 4

PR1Insect
200
300
400
500

PR1PH
5.0
5.5
6.0
6.5

8. Save
Close Mass Results Entry form to return to Sample Summary form.
Close Sample Summary form to return to Sample Groups form.
9. [B] Composite Results
From the Sample Groups form, verify that your sample group is still highlighted.
Select [B] Composite Results
Check Checkbox: Accept (not necessry to check to create composite)
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Check Checkbox: In-Spec (not necessary to check to create composite)

10. [B] Create Composite


11. Disposition of Samples

After you have Created the Composite, return to the Sample Summary form.
Notice that the disposition of your samples is: In Progress OR Complete
IF it is complete, you can change the disposition
From the sample summary form, Select your first Sample
[B] View Sample
[M] Actions > Change Disposition

Exercise 14: Create Spec Validity Rules for Customer


1. Query up Your Spec for XXBDC01
2. Select Validity Rule Button
3. Select Button New
4. Add a Customer Validity Rule
[T] Customer
Field Name
Field Value
Organization
PR1
Status
Defaults to New
Customer
Effective Dates
Control Block
Block Blank
Sample Plan Block
Block Blank

1168
Do not change

Notes
Could leave it blank
Status acts the same as all status controlled
forms.
This is Customer: Bigmart

5. Save
6. Change Status
[M] Actions > Change Status
Field Name
Field Value
Notes
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Change Status To

Approved for General There are pre-built statuses delivered to


Use
customers. But, additional statuses can be
user defined and added.

Optional Validity Rule Exercises


Exercise 15: Spec Validity Rule for Production
1. (T) Production
Field Name
Organization
Status
Recipe
Effective Dates
Control Block
Create Samples
Automatically
Update Inventory
Quantity
Control Lot
Attributes
Lot Optional on
Sample
In Spec
Out Spec
Sample Plan Block
Name

Field Value.
PR1
Defaults to New

Notes
Status acts the same as all status controlled
forms.

<Your Recipe>
Do not change
Checked

Will not create automatically without a


sample plan

Unchecked
Checked
Checked
Good
Hold
Fixed 1 (LOV)

2. Save
3. Change Status
[M] Actions > Change Status
Field Name
Change Status To

Field Value
Notes
Approved for General There are pre-built statuses delivered to
Use
customers. But, additional statuses can be
user defined and added.

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Optional Validity Rule Exercises


WCI buys their sweetener from Winters Supply (the universal supplier of all things
process). They test incoming sweetener as follows:

Exercise 16: Create Spec Validity Rules for Supplier


Note: In order to do this exercise, you must create a new sample plan following
guidelines in exercise 18. Suggestion: Make the plan something realisitic such as 1 lb
per 1 Receipt.
1. [T] Supplier
Field Name
Organization
Status
Supplier
Operating Uni
Site
PO
PO Line
Effective Dates
Control Block
Create Samples
Automatically
Update Inventory
Quantity
Control Lot
Attributes
Lot Optional on
Sample
In Spec
Out Spec
Sample Plan Block
Name

Field Value.
PR1
Defaults to New

Notes
Status acts the same as all status controlled
forms.

5001
Blank
1
Blank
Blank
Do not change
Checked

Will not create automatically without


sample plan

Unchecked
Checked
Unchecked
Good
Hold
<Select Yours from
LOV>

This will be a sampling plan that you


created for this exercise.

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2. SAVE
3. Change Status
[M] Actions > Change Status
Field Name
Change Status To

Field Value
Notes
Approved for General There are pre-built statuses delivered to
Use
customers. But, additional statuses can be
user defined and added.

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SECTION 5: COSTING
Exercise 1: Standard Costing
WCI uses both standard and period weighted average methods for costing. Their costs
for Cost Method STND, Organization PR1, Cost Calendar 08S1, PERIOD 1 have been
hammered out to be:
[N] Financials > Item Costs
Only the Raw Material Costs are entered

Sweetener (XXSW02) - $.45 LB


Cola Extract (XXCE03) - $.75 LB
Artificial Color (XXAC04) - $1.66 LB
Water (XXH2O02) - $0.02 LB

The example below is for Sweetener. Complete for all Raw Materials.
1. Enter Item Standard Cost for Sweetener (XXSW02)
Field Name
Field Value
Notes
Header
Item
XXSW02
Calendar
08S1
Period
1
Cost Type
STND
Line Level
Usage Type
Material
Component Class
1-Material
Code
Analysis Code
VAL
Component Cost
.45
2. Enter Item Standard Cost for Other Raw Materials

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3. Enter Resource Standard Cost for Operator 2 (XX-OP02)


[N] Financials > Resource Costs
Operator 2 (XX1-Op02) - $24.50/Hr
NOTE: all resource costs EXCEPT 1-Op02 are already in the system.
Field Name
Legal Entity
Organization
Resource
Calendar
Period 1
Component Class
Base Currency
Cost Details
Cost Type
Cost

Field Value
PRU
PR1
ZZ-OP02
08S1

Notes

1-LBRDIR
USD
STND
24.50

4. Standard Cost Rollup


[N] Financials > Standard Costs > Cost Rollup
Enter the information shown below for your BDC and then select the [B] Accept
Field Name
Legal Entity
Calendar
Period
Cost Type
From Item

Field Value
PRU
08S1
1
STND
XXBDC01

Notes

5. View Results
[N] Financials > Item Costs
Query up your XXBDC01 to view Standard Costs
6. View Formula Details
From the Cost Detail Screen: [N] Actions > Formula Details
7. View Routing Details
From the Cost Detail Screen: [N] Actions > Routing Details
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Exercise 2: PWAC Costing


Cost Method PWAC information:
Organization PR1, Cost Calendar 08PW, PERIOD 1
You will have to create and receive a PO with Winters Supply for your raw materials.
The vendor prices are:
1. Purchasing
Common Purchasing > Purchase Order > Purchase Orders

Sweetener (XXSW02) 10,000 LB


Sweetener (XXSW02) 30,000 LB
Cola Extract (XXCE03) 10,000 LB
Artificial Color (XXAC04) 10,000LB
Water (XXH2O05) - $.02 LB 10,000LB

$.40 / LB
$.60 / LB
$1.05 / LB
$1.22 / LB
$.02 / LB

2. Receiving
[N] Common Purchasing > Receiving > Receipts
3. Enter Resource PWAC cost
Financials > Resource Costs
Operator 2 (XX1-Op02) - $27.50/Hr
Field Name
Field Value
Notes
Legal Entity
PRU
Organization
PR1
Resource
ZZ-OP02
Calendar
08PW
Period 1
Component Class
1-LBRDIR
Base Currency
USD
Cost Details
Cost Type
PWAC
Cost
27.50
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NOTE: all resource costs EXCEPT XX1-Op02 are already in the system.
4. Complete A Batch
Batch is already completed for this exercise. However, please go back into a batch and
Make sure at least one batch is completed for Actual Cost Methods (In previous releases
the batch needed to be closed)
5. Actual Cost Process for PWAC
[N] Financials > Actual Costs > Actual Cost Process
Complete Actual Cost Process
Field Name
Field Value
Legal Entity
PRU
Calendar
08PW
Period
1

Notes

Select the Button: Accept

Based on this information, what is the PWAC cost for the batches you have run?
What is the actual cost of one of these batches?
6. Actual Cost Process for LAC
Rerun the Actual Cost Process for
Calendar: 08LA
Period: 3
Cost Type: LAC
7. View Actual Transaction Costs
[N] Financials > Actual Costs > View Transactions
Query Up for Your Raw Material: %SW%
Query Up for Your Finished Good: %BDC%

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Exercise 3: Lot Costs


1. Lot Cost Items
[N] Financials > Lot Costs > Setup > Lot Cost Items
NOTE: If you had assigned a Category: Cost Class, at the Master Item you would
not need to enter each item individually
Field Name
Legal Entity
Lot Cost Type
Item
Item
Item
Item
Item

Field Value
PRU
LC
XXBDC01
XXSW02
XXCE03
XXAC04
XXH2005

Notes

2. Lot Cost Process


Financials > Lot Costs > Lot Cost Process
Field Name
Name
Legal Entity
Cost Type
Final Run
Process
Organization

Field Value
Lot Cost Process
PRU
LC
No
PR1

Notes

3. Button: OK
4. Button: Submit

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SECTION 6: LOT GENEALOGY


Exercise 1: Lot Genealogy
[N] Quality Manager > Inquiries > Lot Genealogy
1. From the Radial Button: Inventory
Look up sweetener to see the transactions (and any other Raw Materials)
Look up your XXBDC01 item to see the transactions.
2. From the Radial Button: Inventory
Look up the lot #: QCTEST
3. From the Radial Button: Batch
Query up your batch (es). Drill down on

U R Done

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