AAPL ODM Training Manual - Garments

Artistic Apparels (Pvt.
) Limited
Training Manual
ODM & FGS
A. F. FERGUSON & CO.

CHARTERED ACCOUNTANTS
A member firm of
ODM & OFGS Training Manual
Preface
This manual is intended to provide the guidance to the users of Oracle Discrete
Manufacturing and Oracle Ferguson Garments Solution at AFGI.
Disclaimer: All Forms used by Oracle Discrete Manufacturing Modules are the
Standard Forms developed By Oracle Corporation while Oracle Ferguson Garment
Solution are customized forms developed as per the needs of Garments industries to cover
the planning and manufacturing scenarios.
2
Table of Contents
1 Resources ...................................................................................................................... 4
2 Departments ................................................................................................................. 7
3 Standard Operations .................................................................................................. 10
4 Routings ...................................................................................................................... 12
4.1 Defining a new Routing ....................................................................................... 12
4.2 Copying Routing from another Routing.............................................................. 21
5 Bills of Material (BOM) .............................................................................................. 24
5.1 Defining a New BOM ........................................................................................... 24
5.2 Making changes in BOM...................................................................................... 30
5.3 Copying BOM ....................................................................................................... 35
5.4 De-activating a Component Item from BOM ......................................................40
6 Production Order ........................................................................................................ 42
7 Ratio Plan ................................................................................................................... 47
8 Multiple Cut Production ............................................................................................. 52
9 Cutting Job Completion ............................................................................................. 54
10 Material Charging ................................................................................................... 58
11 Stitching Operation Plan ............................................................................................ 61
12 Multiple Cut Issuance ............................................................................................. 66
13 Stitching Line Output .............................................................................................. 69
14 Material Charging ....................................................................................................71
15 Washing Operation Plan ..........................................................................................71
16 Move Transactions .................................................................................................. 76
18 Job Completion ....................................................................................................... 79
19 Finishing Operation Plan ........................................................................................ 83
20 Move Transaction .................................................................................................... 89
22 Job Completion ....................................................................................................... 89
23 Recut ........................................................................................................................ 90
3
Oracle Discrete Manufacturing

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
4
3. The following window will appear:
4. Define resource name (up to 10 characters) and description for the resource
5. Select the type of resource (Person or machine), unit of measure (Hrs/Lbs),
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 ‘Average Rt.’ and then enter
per unit resource cost and save your work.
5
6
2 Departments
A department is an area which is required to collect cost and apply overheads. Department
is assigned to its relevant operations and the resources which are required to perform that
operation
1. Navigate to the Departments Window

2. Double Click Routings and then Departments
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.
7
4. Enter location for the department i.e. Garment Industries.
8
5. Click on resources button to assign and update resources to the department.

Select the appropriate resource from the resource list of values. Enter no. of units
in Units column.
6. Save your work.
9
3 Standard Operations
Operations are the processes which are required to produce an end product, define
standard operation in order to create relationship between operation and the
department which will going to perform it.
1. Navigate to the Standard Operations Window.

2. Double click on the Routings and then on Standard Operations.
10
3. Enter a unique operation code to identify a standard operation. Operation code

can be up to 4 characters. Enter detailed description for the operation.
4. From list of values, select the department where the operation is performed.
5. Save your work.
11
4 Routings
A routing represents the step–by–step operations that are performed to manufacture a
product and processing sequence in the manufacturing operations. Every Job in the Work
in Process module is based on a Routing.
4.1 Defining a new Routing
1. Switch to “Bills of Material” responsibility and click on “routings”:
12
2. Following window will appear:
13
3. Select the item for which the Routing needs to be defined.
14
4. Enter Sequence of operation and select the Standard operation from the list of
values.
15
5. Go to Operation Yield tab and enter yield if any.
16
6. 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.
7. Unmark the reference check in order to change resources while charging of item
8. Enter the sequence number of the resource and select the resource from list of
values.
9. 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.
10. 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
17
18
11. Enter the number of resource units required (i.e. 1) in scheduling tab.
19
12. In the costing tabbed region, the resource charge type will default from the
defined charge type from resource and can be updated.
20
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:
21
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
22
Note: Once the Routing is copied changes can be made in routing as required.
23
5 Bills of Material (BOM)
Bill of Material (BOM) is a list of components required to manufacture its parent

(assembly) item.
Every scheduling 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:
 Finished Goods
Routing should be created first to enter a bill of material
5.1 Defining a New BOM
Following steps will be followed to define a BOM:
1. Switch to “Bills of Material” responsibility
24
2. Double click the bills and the following form will open:
25
3. Select the item for which the BOM needs to be defined.
26
4. Enter sequence number for the component and select the operation sequence
in which the items will be used.
27
5. Enter consumption of each component in “Quantity” for one unit of item

produced.
Save the BOM.
28
4.1 Making changes in 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
29
30
Press the “Find” icon
31
3. Select the item from list of Values, BOM of which needs changes and press the
“OK” button.
32
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;
5. Select the component; enter the estimated quantity, supply type, sub inventory
and locator. Also refer to BOM creation.
6. Save your work.
33
4.2 Copying BOM
1. Switch to “Bills of Material” responsibility and double click “Bills”
34
2. The following window will open:
3. Select the item for which BOM has to be defined.
35
4. Click on Tools > Copy Bill from as shown in picture below:
36
5. Select the Unit in the Organization field from which you want to copy the BOM
6. Select the Item from which you want to copy the BOM.
7. Press Copy and the BOM will be copied.
37
Note: Once the BOM is copied changes can be made in BOM as required
8. Save your work.
38
4.3 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”
39
3. Select the item to be de-activated.
4. Enter the current or future date in “To” column in Date Effectivity tab as
shown above.
5. Save your work
40
Ferguson Garment Solution

5 Production Order
It is required to allocate order quantity to different inventory organizations as per the
required operations
1. Switch to “Work in Process” responsibility and double click “Production

Order”
2. The following window appear and click the button to select OC number
41
3. Click CMT button to enter detail
42
4. After entering all the detail click back and post the production order
43
6 Ratio Plan
Ratio plan is required to enter the cutting details of fabric as per requirement
1. Switch to “Work in Process” responsibility and double click “Ratio Plan”.
44
2. Following form will appear
3. Select sales order number from LOV

4. Then select Ply Type as single or double ply
5. Select Style by click on button
6. Select OC number from given LOV
45
7. Click save
46
8. Enter numbers of Ply and click on size, all the size detail will get populated
automatically
9. Enter ratio against the size, fill the fabric width and marker length detail
47
10. Extra quantity will be entered in the Ext Quantity at header level
11. Now click item, post and BOM button one after other
 Item: Create item for cutting
 Post: Creates job for cutting
 BOM: Assign component to job
48
7 Multiple Cut Production

Enter multiple cut production in order to issue fabric to production line for cutting
1. Switch to “Work in Process” responsibility and double click “Multiple Cut

Production”.
2. Click new to issue fabric against relevant OC number
3. Now click on show cuts in order to select relevant line from ratio plan
Select all and click “Ok”
49
4. Save the record.

5. Now click on issue to floor button and save again
6. Click post to lock the record (mandatory step)
8 Cutting Job Completion
In order to mark status of cutting job as completed, press “Job Completion” button to run
completion procedure.
50
9 Material Charging
1. Switch to “Work in Process” responsibility and double click “WIP Material
Transaction”.
2. And Select relevant job from LOV
3. Click on continue, the following window will appear
51
4. Select sub inventory, locator and the quantity to be charge against job
52
5. Click done to continue
53
10 Stitching Operation Plan

Stitching operation plan is required to manage cutting jobs for stitching at different date
on the basis of sales order number and inseam size. Stitching line wise quantity is
planned in stitching operation plan.
1. Switch to “Work in Process” responsibility and double click “Stitching

Operation Plan”.
54
2. Following form will appear
3. Enter following detail at header level:

Sales order number
Number of stations to be utilize against the relevant sales order
Target efficiency
Day target of specific unit
Target production allocated to a unit
55
4. Now enter relevant OC number
5. Enter starting date and output date
56
6. Save the line and enter OC line detail

Stitching line
Head of department production and head of department floor.
Quantity allocated to relevant stitching line
Now click on “Operation Detail” tab
7. Click on OP Fetch button in order to fetch detail regarding operation from style
bulletin
Mark select all
Click Post button
8. Operations should already be defined in style bulletin in order to fetch operations.
Otherwise operations would be filled manually.
57
9. Now re select OC Detail tab and click on “Job” and “Op and Mat” button to created
job and assign operations respectively.
Now click Resource button on operation detail tab
58
11 Multiple Cut Issuance

Enter multiple cut issuance in order to issue cut fabric to production line for stitching
1. Switch to “Work in Process” responsibility and double click “Multiple Cut

Issuance”.
2. Enter relevant OC number
59
3. Enter stitching line and click Ctrl+s to save the header
60
4. Now mark all the cut quantity and then press Post
61
12 Stitching Line Output

It is required to record output from stitching line against OC Number
1. Double click “Stitching line output”.
2. Enter relevant sales order , OC number and operation line
62
3. Enter Cut number, the output quantity and rejected quantity
4. Save the records.

5. Click on Post and Job Completion.
63
13 Material Charging
Refer to point 9
14 Washing Operation Plan

1. Switch to “Work in Process” responsibility and double click “Washing
Operation Plan”.
64
Following form will appear
2. Enter Sales order number
3. Now enter following in OC detail

 OC Number
 Execution Date
 Output Date
65
4. Now enter following detail in style process. These detail are required to perform
multiple washing operation over garment.
 Sequence number of washing operation
 Department that perform the operation
 Select relevant operation in that department
 Enter additional detail if required such as water required, temperature, and time
piece per min
66
5. Enter chemicals and their quantity in process details that is required to be perform
on that particular operation.
10. Select Operation tab and click on OP Fetch button (Note: Operations should already
be defined in style bulletin in order to fetch operations. Otherwise operations
would be filled manually.)
67
6. Now mark all the operation as post and re move to OC Details tab
7. Click on Job and Mat & Operations button
8. Then click resource button on Operations tab to allocate resources.
68
15 Move Transactions
1. Switch to “Work in Process” responsibility and double click “Move
Transactions”.
Following window will appear
69
2. Enter Job name (Same as Sales Order Number)
70
3. Enter sequence number from LOV and move the inventory from queue to the move
of next department
4. Enter moved quantity and click save
Refer to point 9
71
17 Job Completion
After completing the relevant operations we are required to perform the following steps
in order to mark the job as complete.
1. Switch to “Work in Process” responsibility and double click “Completion

Transactions”.
72
2. Following window will appear
3. Find the relevant Job
4. Now click the continue button the following form will appear
73
5. Now enter following detail of the items which has been completed against relevant
Job:
 Sub inventory
 Locator
 Quantity Completed
 Lot
74
Click done
75
18 Finishing Operation Plan

1. Switch to “Work in Process” responsibility and double click “Finishing
Operation Plan”.
76
Following form will appear
2. Enter sales order number

3. Enter following additional detail
 Target efficiency
 No of stations
 Target production
77
Enter OC Details
 OC Ref/no
 Execution date
 Output date
1. Now click on Operations which will be populated automatically.
2. Select Operation details tab and click OP Fetch button
(Note: Operations should already be defined in style bulletin in order to fetch

operations. Otherwise operations would be filled manually.)
78
79
3. Mark all the operation as post.
80
4. Click Job and OP & Mat button
5. Now select operation details tab and click on resource button
81
19 Move Transaction
Refer point 15
Refer to point 9
21 Job Completion
Refer point 17
82
22 Recut
In case of recut quantity the user need to start from production order
NOTE: Recut must be done after completing current or existing Cutting & Stitching job
against sales order.
- Switch to “Work in Process” responsibility and double click “Production

Order”.
1. The following window appear and mark the recut checkbox
83
2. As you mark the recut checkbox, Recut button get active
Now click the Recut button
3. Enter the inseam and its recut quantity
84
4. Now click on Recut Department button to assign recut quantity to different

inventory organization if required.
Click save after assign org.
85

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Artistic Apparels (Pvt.

A. F. FERGUSON & CO.

Oracle Discrete Manufacturing

1. Switch to Bills of Material Responsibility

3. The following window will appear:

1. Navigate to the Departments Window

4. Enter location for the department i.e. Garment Industries.

5. Click on resources button to assign and update resources to the department.

6. Save your work.

1. Navigate to the Standard Operations Window.

3. Enter a unique operation code to identify a standard operation. Operation code

5. Save your work.

4.1 Defining a new Routing

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

2. Following window will appear:

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

5. Go to Operation Yield tab and enter yield if any.

6. Click on Operation Resources and select the resources working on respective

4.2 Copying Routing from another Routing

5 Bills of Material (BOM)

Bill of Material (BOM) is a list of components required to manufacture its parent

Routing should be created first to enter a bill of material

5.1 Defining a New BOM

Following steps will be followed to define a BOM:

1. Switch to “Bills of Material” responsibility

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

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

Save the BOM.

4.1 Making changes in BOM

Following steps will be followed to define a BOM:

1. Switch to “Bills of Material” responsibility

Press the “Find” icon

4. Make changes as required and save your work.

4.2 Copying BOM

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

2. The following window will open:

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

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

7. Press Copy and the BOM will be copied.

8. Save your work.

4.3 De-activating a Component Item from BOM

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

3. Select the item to be de-activated.

Ferguson Garment Solution

1. Switch to “Work in Process” responsibility and double click “Production

3. Click CMT button to enter detail

1. Switch to “Work in Process” responsibility and double click “Ratio Plan”.

2. Following form will appear

3. Select sales order number from LOV

6. Select OC number from given LOV

7 Multiple Cut Production

1. Switch to “Work in Process” responsibility and double click “Multiple Cut

Select all and click “Ok”

4. Save the record.

8 Cutting Job Completion

3. Click on continue, the following window will appear

5. Click done to continue

10 Stitching Operation Plan

1. Switch to “Work in Process” responsibility and double click “Stitching

2. Following form will appear

3. Enter following detail at header level:

4. Now enter relevant OC number

5. Enter starting date and output date

6. Save the line and enter OC line detail