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Oracle Discrete Manufacturing

Training Material

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1. Resources ............................................................................................................................................... 3
2. Departments ........................................................................................................................................... 6
3. Standard Operations ............................................................................................................................ 10
4. Routings ................................................................................................................................................ 13
4.1 Defining a new Routing................................................................................................................. 15
4.2 Copying Routing from another Routing ........................................................................................ 22
5. Bills of Material (BOM) ......................................................................................................................... 25
5.1. Defining a New BOM .................................................................................................................... 27
5.2. Making changes in BOM ............................................................................................................... 33
5.3. Copying BOM ................................................................................................................................ 39
5.4. De-activating a Component Item from BOM ................................................................................ 45
6. Discrete Jobs ......................................................................................................................................... 47
6.1. Job Release ................................................................................................................................... 53
6.1. Update Material Requirement ..................................................................................................... 55
7. Move Order Requisition ....................................................................................................................... 59
8. Transact Move Order............................................................................................................................ 66
9. WIP Material Transaction ..................................................................................................................... 69
8.1. WIP return .................................................................................................................................... 69
8.2. WIP Extra Issue ............................................................................................................................. 73
10. WIP Move Transaction ......................................................................................................................... 80
11. Completion Transaction ....................................................................................................................... 86
12. Job Close ............................................................................................................................................... 93
13. Sub-inventory Transfer ......................................................................................................................... 98
14. Review Job Status, Job Close and Job Costing .................................................................................... 105
15. Viewing WIP Material Transactions.................................................................................................... 110
16. Viewing WIP Value Summary ............................................................................................................. 112
17. Work order less completion ............................................................................................................... 115
18. Recording of Waste ............................................................................................................................ 120
19. Non-standard Job ............................................................................................................................... 129
20. Quality ................................................................................................................................................ 145
21. Running Report ................................................................................................................................... 150

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1. Resources
Resources are defined as anything of value, except material and cash, required to manufacture,
cost and schedule products. Resources include people and machines.
Following steps will be followed to define a resource:

1. Switch to Bills of Material Responsibility

2. Double click Routings and then Resources

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3. The following window will appear:

4. Define resource name (upto 10 characters) and description for the resource
5. Select the type of resource (Person or machine), unit of measure (Hrs), charge type
(WIP move) and basis of charging the resource (Item).
6. Check the ‘Costed’ flag in order to charge Jobs with the cost of the resource
7. Select the absorption account to offset resource charges earned in work in process
8. Select the variance account.
9. Click on “Rates Tab” to enter, select the cost type as ‘Prep. Avg.’ and then enter per unit
resource cost and save your work.

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2. Departments

1. Navigate to the Departments Window

2. Double Click Routings and then Departments

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3. Enter a name for the Department and its Description unique for the Organization. You
can also enter an inactive date on which you can no longer assign this department to
routing operations.
4. Enter location for the department i.e. Diamond tyre Factory.

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5. Click on resources button to assign and update resources to the department. Select the
appropriate resource from the resource list of values. Enter 1 units column.

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6. Save your work.

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3. Standard Operations

1. Navigate to the Standard Operations Window.

2. Double click on the Routings and then on Standard Operations.

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3. Enter a unique operation code to identify a standard operation. Operation code can be
upto 4 characters. Enter detailed description for the operation.
4. From list of values, select the department where the operation is performed.

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5. Choose the Operation Resources button to assign resources to the Standard operation.
6. Enter the sequence number of the resource and select the resource from list of values.
7. Select a basis type (Item) by which to charge and schedule the resource. The default is
the basis specified for the resource:
 Item: Select Item when your charges fluctuate with quantity change.
 Lot: Select Lot when your resource usage quantity is the amount required per job
or schedule, for example, setup charges.
8. Enter usage of resource per unit in either the Usage or Inverse fields:
 Usage: Hours consumed for one unit of item produced.
 Inverse: Production per hour

9. Save your work.

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4. Routings

A routing represents the step–by–step operations that are performed to manufacture a product.
Routing represents the processing sequence in the manufacturing operations. Every Job in the
Work in Process module is based on a Routing. For normal production process, routing of the
following items will be created for DTL:
 Semi-Finished Items
 Finished Items
Following table contains list of semi-finished and finished items.

Item assembly Assembly type

Compound Semi-finished

Bicycle tube Finished

Trolley tube Finished

Rickshaw tube Finished

Motorcycle tube Finished

Ply Semi-finished

Bead wire Semi-finished

Air bag Semi-finished

Bicycle tyre Finished

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Item assembly Assembly type

Trolley tyre Finished

Motorcycle tyre Finished

Rickshaw tyre Finished

Rim tape Finished

Rim flap Semi-finished

Motorcycle tyre-tube-rim tape set Finished

Rickshaw tyre-tube-rim flap set Finished

B, C and D Grade Items

Finished

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4.1 Defining a new Routing

1. Switch to “Bills of Material” responsibility and click on “routings”:

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2. Following window will appear:

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3. Select the item for which the Routing needs to be defined.

4. Enter Sequence of operation and select the Standard operation from the list of values.

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5. Click on Operation Resources and select the resources working on respective assembly,
enter the basis of charging the resource unit as Item for charging on the discrete job.
The resources will default from the operations window. These can be updated.

6. Enter the number of resource units required (i.e. 1).

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7. In the costing tabbed region, the resource charge type will default from the defined
charge type from resource and can be updated.

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4.2 Copying Routing from another Routing

1. On the Routings form, select the item for which you want to create a Routing
2. Click on Tools > Copy routing from as shown in picture below:

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3. Select the Unit in the Organization field from which you want to copy the routing
4. Select the Item from which you want to copy the Routing
5. Press Copy and the Routing will be copied

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Note: Once the Routing is copied changes can be made in routing as required.

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5. Bills of Material (BOM)

Bill of Material (BOM) is a list of components required to manufacture its parent (assembly)
item.
Every job in the Work in Process module is based on a Bill of Materials. For normal production
process BOM of the following items will be created:
 Semi-finished Goods
 Finished Goods
Following table contains list of semi finished and finished items.

Item assembly Assembly type

Compound Semi-finished

Bicycle tube Finished

Trolley tube Finished

Rickshaw tube Finished

Motorcycle tube Finished

Ply Semi-finished

Bead wire Semi-finished

Air bag Semi-finished

Bicycle tyre Finished

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Item assembly Assembly type

Trolley tyre Finished

Motorcycle tyre Finished

Rickshaw tyre Finished

Rim tape Finished

Rim flap Semi-finished

Motorcycle tyre-tube-rim tape set Finished

Rickshaw tyre-tube-rim flap set Finished

B, C and D Grade Items

Finished

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5.1. Defining a New BOM

Following steps will be followed to define a BOM:

1. Switch to “Bills of Material” responsibility

2. Double click the bills and the following form will open:
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3. Select the item for which the BOM needs to be defined.

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4. Enter sequence number for the component and select the operation sequence in which the
items will be used.

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5. Enter consumption of each component in “Quantity” for one unit of item produced.

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6. Click on the “Material Control” tab and enter the following:

 Supply Type: Operation pull
 Supply “Sub inventory” and “Locators”: Mixing, Callender, Bead wire etc.

7. Save the BOM.

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5.2. Making changes in BOM

Following steps will be followed to define a BOM:

1. Switch to “Bills of Material” responsibility

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2. Double click the bills and the following form will open

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Press the “Find” icon

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3. Select the item from list of Values, BOM of which needs changes and press the “OK”
button.

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4. Make changes as required and save your work.

Note: You can also add new component items to BOM by clicking ‘New’ icon after placing
the cursor on any of the BOM lines;

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5. Select the component; enter the estimated quantity, supply type, sub inventory and
locator. Also refer to BOM creation.
6. Save your work.

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5.3. Copying BOM

1. Switch to “Bills of Material” responsibility and double click “Bills”

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2. The following window will open:

3. Select the item for which BOM has to be defined.

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4. Click on Tools > Copy Bill from as shown in picture below:

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5. Select the Unit in the Organization field from which you want to copy the BOM

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6. Select the Item from which you want to copy the BOM.

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7. Press Copy and the BOM will be copied.

Note: Once the BOM is copied changes can be made in BOM as required

8. Save your work.

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5.4. De-activating a Component Item from BOM

1. Select the Item for which the component needs to be deactivated.

2. On the BOM form, click the tab titled “Date effectivity”

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3. Select the item to be de-activated.

4. Enter the current or future date in “To” column.

5. Save your work.

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6. Discrete Jobs
The authorized user will create production jobs for each sub assembly and assembly to be
produced against as per production plan. For following items, discrete jobs will be created as
shown below:

 Compound
 Ply
 Bead wire
 Air bag
 Rim tape
 Rim flap

Following are the steps to be followed to create a Job:

1. Switch to the “WIP” responsibility
2. Navigate to Discrete > Discrete Jobs

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3. Double click the discrete job, the following screen will open:

4. Enter the relevant job number and assembly and click on “Find” to find any existing job.
5. Click on “new” to create a new job.

6. For all discrete jobs, ensure that the following information has been entered:
 Job name (It can be entered manually or the system will auto generate a unique
job number. It should be unique for each new job).
 Assembly Item
 Class (It will default)
 Start quantity
 Start date (Relevant date will default)

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7. Click on “Save Tab” to save the job

8. C`lick on the operations button to view the departments on which the operations for
this item are being incurred.

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9. Click on the components button and you will get to see material requirements as
defined in the BOM (bills of materials) for the product to be manufactured in this
job.

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10. You can also view the quantities of components required for this particular job, how
much of the have been issued, and how much still are required.

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6.1. Job Release

In order to start the production process, the authorized user will release the relevant job for
Production.
1. For releasing the job, the user will query the job in the Discrete Jobs window and
change the status of the job from ‘Unreleased’ to ‘Released’.

2. For compound jobs only, user will select the relevant routing based on the
banbury machine to be used for mixing.

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3. Save your work.

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6.1. Update Material Requirement

1. Go to Job/schedule details and select material requirement.

2. Enter relevant job no. and click on find. All the raw materials required will be listed as shown
below.

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3. Select the item to be deleted. Click on edit and click delete.

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4. Select the component required for the job as shown below.

5. In quantities tab enter the quantity required per unit of item to be produced.

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6. In supply tab enter the supply type (operation pull), sub inventory (mixing) and locator.

7. Save your work (ctrl+s).

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7. Move Order Requisition

The user will run move order transfers for ‘Raw Material from raw material store’ and
‘compounds from compound store’ in order to transfer it from its respective sub-inventory to
production floor.

This is Internal Requisition raised by user department to the stores department to issue Material
to Shop-floor.

1. Go to inventory>Move Orders

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2. Following window will appear:

Note: Sequential number will be automatically assigned to move order upon

completion. Optionally enter description

Note: The Status field displays Incomplete until the move order is approved.

3. If all the items are to be transferred from a single sub inventory, user will enter source
sub inventory at header level. If the items are to be transferred from multiple sub
inventories, user will select source sub inventories at line level. Source sub inventory
will be main store for raw materials and compound store for compound items.

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4. At Line Level enter following information

 Item
 Primary quantity
 Source sub inventory and locator
 Destination sub inventory and locator
 Transaction Type (In case of Sub-inventory transfer, user will select the transaction
type of Move Order Transfer)

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5. Click Approve to submit the move order requisition for approval. Approval notification
will be sent to relevant personnel.

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8. Transact Move Order

8. Switch to inventory responsibility.
9. Go to move order>transact move order.

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10. Enter the requisition number to be transacted in the following window and click on find.

11. Click on view/update allocation.

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12. Select the relevant sub inventory, locator and enter the issuance quantity. Click on Lot/serial button
as shown below.

13. Enter the relevant lot number from which the item has to be issued and enter issuance quantity.
Click on done and then click on transact.

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9. WIP Material Transaction

There are following types of WIP material transactions.

9.2. WIP Return

9.2. WIP Extra Issue

8.1. WIP return

1. In order to process return of material from production job to store, the user will
select ‘WIP Return’ transaction type in the Material Transactions window. The user
will select “Specific Component”. Press Continue.

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2. Select specific component to be returned. The sub inventory from which the
component was issued, and the locator; will default.

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3. The user will also select operation sequence and enter the return quantity.

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4. If the item is lot controlled, select the relevant lot number. Also, enter the return
quantity. Click done to proceed.

5. Press the done button to complete the transaction

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8.2. WIP Extra Issue

This functionality will be used to issue any component (raw material) to job, that is not defined in BOM or
to charge additional quantity of any component defined in BOM. This functionality can be used to issue
raw material to job at any time before closing the job.

1. Navigate to the “WIP Material transactions” window and double click it.

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2. The following window will open:

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3. Enter the relevant job number to which extra material issuance is required.
4. Select the transaction type “WIP Issue”.
5. Check the “Specific Component” if the extra issuance is of a specific component.

6. Click the “continue” button.

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7. User will enter the following details.

 Relevant component code
 Sub inventory and locator from where the component has to be issued
 Operation sequence number of operation in which the component is required.
 Required Quantity of the component

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8. Click on lot/serial.

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9. Select Lot/Serial Number. Enter lot quantity required. Click done.

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10. Click the “Done” button.

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10. WIP Move Transaction

A move Transaction is processed to record the production of each department.

The data entry of each process is discussed as follows:
After the discrete job is created and released, its department wise production will be recorded
as follows;

1. Switch to “Work in Process “responsibility and Navigate to Move Transaction > Move
Transactions
2. Double click the move transaction.

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The following window will open:

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3. Select the job number from the list of values;

From “Operation Sequence” with step ‘Queue’

To “Operation Sequence” with step ‘To move’

4. Job quantity will default in the quantity field. User will enter the production quantity.
5. Enter the production date or accept the default.

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6. After entering production quantity, user will have option to enter in-process quality
results. Quality plans will be attached to move transaction form. User will click on the
quality tab to open relevant quality form.

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7. Following form will open. User will enter the results and click OK.

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8. Click the “Save” button. On saving, following window will open. Quantity to be issued to
production job will default on the basis of required quantity as per BOM. User will click on
done to record production and charge components to production job.

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11. Completion Transaction

Completion transaction is used to “inventorise” the item produced in relevant sub
inventory of production floor.

1. To complete the discrete job, user will navigate to Material Transactions > Completion
Transactions

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The user will double click Completion Transaction and select the Job Number from the list of
values. On selecting the Job number, the information relating to that Job will default on the
form.

2. The user will enter the production date or accept the default,

3. Click the continue button.

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4. Enter sub inventory and locator where the completed items are to be inventorized after
production.

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5. Enter the total Quantity produced.

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6. Press the Lot/Serial button on the Completion Transaction Form for lot controlled items.
Lot numbers can be automatically generated or manually entered. Enter the lot quantity
and click on done.

Note: Lot entry will only be applicable for lot controlled items.

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7. Select compound production in the context value as shown below.

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8. Enter Relevant shift for production job and no. of batches as shown below. Click Ok.

9. Click done to finish WIP completion transaction.

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12. Job Close

Once the job is complete, it is advisable to change the status of the job to close. Until the job is
closed, the user has the option of charging material, resources and overheads to the job.

1. Switch to “WORK IN PROCESS” responsibility

2. Double click the “Discrete Jobs”

3. Double click close discrete job and then double click close discrete job (form).

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The following window will open

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4. Enter the Job number and click on find. Following window will open.

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5. Go to the “tools” and click on close 1

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6. Select the report type and click ok.

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13. Sub-inventory Transfer

‘Sub-inventory transfer’ functionality will be used to transfer sem-finished and finished items from one
location to another. This functionality will be used in the following scenarios:

 Transfer of compound items from mixing shopfloor to compound store.

 Transfer of packed bicycle and trolley tubes from BC tube shopfloor to finished goods store.
 Transfer of rejected bicycle and trolley tubes from rejection shopfloor to rejection store.
 Transfer of motorcycle tubes from MC tube shopfloor to Honda, OEM, Local or Export sub-
inventories.
 Transfer of rickshaw tubes from MC tube shopfloor to MC tyre shopfloor.
 Transfer of rejected motorcycle and rickshaw tubes from rejection shopfloor to rejection store.
 Transfer of packed rim tapes from MC Tyre shopfloor to finished goods store.
 Transfer of packed bicycle and trolley tyres from BC Tyre shopfloor to finished goods store.
 Transfer of rejected bicycle and trolley tyres from rejection shopfloor to rejection store.
 Transfer of bead wires and ply from bead wire shopfloor and calendar shopfloor to relevant tyre
departments.
 Transfer of packed motorcycle tyres from Honda, OEM, local or export subinventories to finished
goods store.
 Transfer of rejected motorcycle and rickshaw tyres from rejection shopfloor to rejection store.
 Transfer of packed tyre-tube-rim tape set from Honda, OEM, local or distributor to finished goods
store.
 Transfer of packed tyre-tube-rim flap set from MC Tyre to finished goods store.
 Transfer of waste from relevant shopfloor to waste yard.

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1. Switch to “INVENTORY” responsibility.

2. Now click the “Transactions” button.

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3. Double click the “Subinventory Transfer”, and select Subinventory transfer on

Transaction Type

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4. Select the item to be transferred.

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5. Select the source Subinventory and locator.

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6. Select the destination Subinventory and locator.

7. Enter the quantity to be transferred. Quantity to be transferred cannot exceed the quantity
available in source Subinventory.
8. Select the relevant lot/serial number from which the Subinventory transfer is made. Also, enter
the quantity to be transferred from the lot. Click on done.

Note: Lot entry will only be applicable for lot controlled items.

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9. Save the progress.

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14. Review Job Status, Job Close and Job Costing

1. Switch to “WORK IN PROCESS” responsibility

2. Double click the “Discrete Jobs”

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3. Enter the job name and press the “Find” button.

Note: The quantity completed shows the production against this job.

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4. Now click the “operations” button

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5. Go to the Quantities tab

 There should be no balance in “To Move” column

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6. Now press the “Components” button

 The “Issued” column shows the quantities issued to job.

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15. Viewing WIP Material Transactions

1. Switch to “WORK IN PROCESS” responsibility, navigate to Material Transactions > View

Material Transactions and double click it

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 We can find the material transaction for a specified date range, specified item (input as
well as output), specified sub inventory, specified lot, specified job and specified
transaction types.

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16. Viewing WIP Value Summary

1. Switch to “WORK IN PROCESS” responsibility, navigate to Discrete Job> WIP Value

Summary and double click it. Following screen will appear:

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2. Select the Job Number and press the find button.

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Note: You can view the Value Summary as well as the transactions relating to relevant
Job.

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17. Work order less completion

Work order less completion functionality will be used for recording production
of following items:
 Tyre-tube-rim tape set for motorcycle
 Tyre-tube-rim flap set for rickshaw
 B, C and D Grade Items

1. Switch to “work in process” responsibility and double click “material transaction and
then ‘Work Order Less Completion’.

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2. Following window will open :

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3. Enter the relevant assembly to be produced and the system will automatically assign
the “Schedule number” or user defined unique schedule number can also be entered.
4. Enter the following data:
 Quantity
 Completion sub-inventory: It will be local or export.
 Completion locator

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5. View the details of component items of relevant assembly by clicking on “Components”

tab. Select the relevant Subinventory and supply locator for tyre item i.e. local tyres or
export tyres.

6. Click ok and then save to save your work.

Note: For recording production of tyre-tube rim flap set for rickshaw and B, C and D grade
items, completion sub-inventory and supply sub-inventory will default. It will not require any
changing.

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18. Recording of Waste

1. Switch to “INVENTORY” responsibility

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2. Navigate to Transactions > Miscellaneous Transactions and double click it. The
following window will appear.

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3. Enter date or accept the default date.

4. Select the Transaction type “Miscellaneous Receipt”.

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5. After opening transaction lines, select the relevant waste items.

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6. Allocate relevant sub-inventory to waste item.

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7. Enter locator value and waste quantity.

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8. Select relevant account for recording waste items. Click on OK.

9. For scorched compound and ply waste enter the following:

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10. In context value select compound waste or ply waste.

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11. For compound waste, enter shift and department.

12. For Ply waste, enter shift and fault.

13. Click on ok and save your work.

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19. Non-standard Job

Authorized user in Mixing Department will run non-standard job for natural rubber on daily basis. The job
will consume relevant natural rubber (e.g. SIR 20, RSS, SLR-20 etc.) and will convert it into logical item
named natural rubber. This logical item with the name of natural rubber will be assigned as component in
the BOM of Compound. As a result, user will not need to change the rubber component in BOM of
compound.

1. Navigate to Discrete>discrete job.

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2. Double click the discrete job, the following screen will open:
3. Click the New button.

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4. The following window will appear:

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5. Select the type “Non-standard”

6. Enter the Job assembly
7. Select the accounting class
8. Enter the required quantities
9. Select the start and completion dates

10. Save the Job.

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11. Navigate to the Job schedule details double click it, and then double click material
requirements.

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12. The Following window will appear:

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13. Enter the relevant job number. Click on find.

14. Enter the required natural rubber to be consumed.

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15. In the supply tab, select the relevant supply type (assembly pull), Subinventory
(Mixing shopfloor), and locator.

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16. Enter Job number on Job completion form. Click on continue.

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17. Enter relevant sub-inventory (mixing shopfloor), locator, and quantity to be completed.

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18. Quantity and lot number will default. User will have option to change lot number.

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19. To close this job, double click close discrete job and then double click close discrete jobs (
Form)

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20. The following window will open:

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21. Enter the Job number.

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22. Go to the “tools” and click on close 1

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23. Select the report type and click ok.

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20. Quality

1. Navigate to Quality responsibility the following window will appear:

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2. Select results then entry.

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3. Navigate to enter quality results window and select relevant quality plan.

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4. Relevant quality plan will appear on the window.

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5. Enter the Job number, item code, shift, and other relevant collection elements e.g. joint leak,
punch, etc.

6. Save your work to complete quality entry.

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21. Running Report

1. Click on View and then on Request

2. Click on Submit a New Request button

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3. Click “submit a new request”

4. Click “Ok”.

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5. Select the name of the report.

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6. Fill the parameters as shown in the window below;

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7. On the next window click Submit and click No to Submit the Request

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8. Navigate to view button on top, select requests. The following window will appear:

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9. Press Find.

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10. Click on View Output to see the report

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