JD Edwards EnterpriseOne

Manufacturing
Lean Execution
Overview

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 Traditional Manufacturing vs. Lean Execution
Discrete Mfg Parent Item • Cumulative quantities and cost
Single snapshot of End Item recorded on the Work Order
Parts List and Routing Work Order • Single Level
Work Centers
when attached to the • Completion recorded on the Work
Work Order Order
Routing Labor
Components
• Labor is recorded on the Routing
• Material is recorded on the Parts List
Parts List
PDM Material
Daily Plan
• Each instance of completion records the
completion, material issued, and labor
End Item
Multi-Level,
Lean Mfg Transaction
No Work Order!
Production Data Labor Data

refreshed from PDM • Ease of updates of production data to

daily or as frequently Production introduce ECO change.
as needed Data Material • Full transaction reversal supported

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Lean Execution
Application Setup and Completions
Shop Floor Daily Plan Shop Floor Daily Plan Item Completions
Definition Completion

• Define Demand • Search Daily Plan Records • Increases Inventory for End Item
• End Item • End Item • Sales Order Number • Decreases Inventory for Components
• Quantity • Line/Cell • Sales Order Type • Mfg Accounting Requirements
• Sales Order • Shift Code • Completion Date • Creates Labor Transactions
• Schedule Production • Select Record to: • Creates Routing Transactions
• Completion Date • Report Completion • Creates Parts List Transactions
• Line/Cell • Review Transactions • Updates Daily Plan
• Shift

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Lean Execution
Application Review Transactions
Shop Floor Daily Plan
Review Transactions
• Review Completion Information
• Sub Assemblies • Date
• Location/Lot • Line ID
• Quantity Completed/Scrapped
• Select Transaction to:
• Review Transaction Details
• Review Production Costs
• Reverse Transaction
Shop Floor Daily Plan Shop Floor Daily Plan
Transaction Details Production Cost Review
• Review Material Issued • Review Cost Amounts
• Review Standard Labor Recorded • Review Cost Units
• Review Purchased Orders Received • Review Variances
• Engineering
• Planned
• Actual
• Calculated at Runtime
• Review Summarized Totals
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Lean Execution
Process Flow

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 Create Production Schedule (Daily Plan) by
Lean Execution creating records based on Item Number, Quantity
Process Flow and Sales Order Number.

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Lean Execution
Shop Floor Daily Plan Definition

1 1) Line/Cell and Shift Defaulted

from Processing Options
2
2) Search for Daily Plan Records
based on Filter Fields
3
4 3) Review End Items
4) Review Previous Completion
and Scrapped Quantities
5) Add, Edit, Copy or Delete
Daily Plan Production
Records
5

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 Lean Execution
Shop Floor Daily Plan – Edit Item

1
1) Select Daily Plan Record for
Editing
2) Input Production
Information
2 3) Input Optional Sales Order,
Location and Lot Information
4) Improved Usability by
Allowing Multiple Records to
3 be Entered

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 Create Production Data before
Lean Execution Completion Processing to reduce
Process Flow Processing Time.

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Lean Execution Perform Completion of End Item by
selecting Daily Plan record.
Process Flow

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Lean Execution
Shop Floor Daily Plan Completions

1) Line/Cell and Shift Defaulted from

1 Processing Options
2
2) Search for Daily Plan Records based
on Filter Fields
3) Review Planned Completion Date
and Quantities
3 4 5 4) Review Previous Completion and
Scrapped Quantities
5) Review Last Transaction Date, Lot,
Location

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 End Item and Related Sub-Assemblies
Lean Execution completed through a Single User
Process Flow Request. This includes reporting of
material and labor used, end item
completed/scrapped quantities and related
costs.

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Lean Execution
Item Completions – Complete Item

1) Shift and Completion Date

Defaulted
2) Input Quantity Completed and
1 4 Scrapped for End Item.
3) Location/Lot for End Item Defaulted
from Daily Plan or Entered by User
2 5
4) Review Planned Quantity and
Completion Date
3 6 5) Review Related Sales Order
6) Review Previous Transaction
Quantities

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Lean Execution Perform Item Completions
Process Flow without defining a Daily Plan.

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Lean Execution
Ad Hoc Item Completions

1 1) Input Item Number

2) Line/Cell and Shift Defaulted from
Processing Options
2
3) Current Date Defaulted for
3 Completion Date or Entered by User
4) Input Quantity Completed and
4 Scrapped for End Item.
5) Location/Lot for End Item Defaulted
5 from Primary or Entered by User
6) Submit Transaction for Processing and
Create Next Transaction

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Lean Execution Multi-Level Backflush of material
Process Flow and labor, reporting of costs and
update of inventory for end items.

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Lean Execution
Process Flow Review Components’ Material and
Labor, Costs and Variances Reporting
Reverse Added in Error Transactions

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Lean Execution
Item Completions – Review Transactions

1) Search for Transactions

based on Filter Fields
1 2) Review Transactions
Quantities
3) Multi-Level Backflush
creates Transactions of
Parent and Sub-
2 Assemblies
4) Reverse Transactions
4
2 3

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Lean Execution
Transactions – Material and Routing

1
1) Review Issued Qty for
Components
2) Review Standard
Labor and Machine
Hours Used

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Lean Execution
Production Costs – Amounts and Units
1
1) Review each
2 3
Transaction

2) Summarized Totals for

Amounts and Units

3) Review Standard,
Current, Planned and
2 3
Actual Amounts and
Units

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Lean Execution
Production Costs - Variances

2 1) Summarized Totals
for Each Item

2) Review Standard,
Current, Planned
1 and Actual
Variances

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Lean Execution
Mixed Mode Manufacturing
Parent Item
P/L - Rtg
Kanban
Work Order
TQC Cell Assembly Machining
Kanban 2 Cell 2 Cell 3
Sub-Assembly Line
Inventory

RIP
Kanban Kanban Kanban

Machining Machining Assembly

TQC Cell 1
Cell 1 Cell 2 Cell 1
Main Production Line

Vendor Managed
Inventory
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Lean Execution
Take Aways
Shop Floor Plan Demand Flow© Manufacturing Integration
• Define Demand based on Item • Completion of DFM Daily Plan
• Define Demand based on Sales Order • Update of DFM Plan
• Define Location/Lot for End Item • BOM Explosion from Line Design
• Define Plan Completion Date • Kanban Management including:
• Plan Production based on Line/Cell • Raw-In-Process Kanbans
• Dual Card Kanbans

Item Completions Standard Costing

• Multi-Level Super Backflush • Supports Standard Costing
• Record End Item Completion • Frozen
• Complete to Daily Plan • Engineering
• Complete Ad Hoc Item (No Daily Plan) • Planned
• Native to Manufacturing Management • Actual
• Reversal of Transaction • Variances
• Ease of ECO Updates to Production • Enhanced Reporting

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Copyright © 2015, Oracle and/or its affiliates. All rights reserved. |