GG - Training Manual (OPM Product Development)

GHANI GROUP OF COMPANIES
TRAINING MANUAL
(OPM PRODUCT DEVELOPMENT)
A. F. FERGUSON & CO.

CHARTERED ACCOUNTANTS
A member firm of ne
TABLE OF CONTENTS
1 PROCESS PARAMETERS ................................................................................................... 1
2 RESOURCES ..................................................................................................................... 3
2.1 GENERIC RESOURCE ............................................................................................................. 3
2.2 PLANT RESOURCES .............................................................................................................. 6
2.3 OSP RESOURCE .................................................................................................................. 8
3 ACTIVITIES....................................................................................................................... 8
4 PROCESS OPERATIONS .................................................................................................... 9
5 PROCESS OPERATION CLASSES ...................................................................................... 15
6 PROCESS ROUTINGS ...................................................................................................... 15
7 PROCESS ROUTING CLASSES .......................................................................................... 18
8 FORMULAS.................................................................................................................... 19
9 RECIPES ......................................................................................................................... 22
10 RECIPE APPROVAL ......................................................................................................... 29
TRAINING MANUAL OPM-PRODUCT DEVELOPMNET
1 PROCESS PARAMETERS
Processing parameters are used to provide operators with information needed for managing
equipment that is used during the preparation of a product.
Setting up Process Parameters
To define a Process Parameter,
Navigate to Process Engineer > Set Up > Process Parameters
Define Parameters
1. Navigate to the Process Parameters window.

2. Enter the Process Parameter name. Required. This field stores the process
parameter (speed, temperature, etc.) and is the first field in a list of values displaying
process parameters. Once the record is saved, this field is not updateable and the
process parameter name must be unique.
3. Enter a Description for the process parameter. Required.
4. Enter a Parameter Type for the process parameter. Required. This field cannot be
changed once the record is saved. Values for this field are:
Text
If the Parameter type is Text, then the process parameter accepts any alphanumeric free
text which is not validated. Once this value is selected, the fields associated with the
Numeric Range, Units, and the list of values buttons are disabled.
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Numeric Range
If the Parameter Type is Numeric value, then you can enter the Minimum, and Maximum
values, and the Units field. Once this type is selected, the fields associated with the list of
values are disabled.
1. Enter the Parameter Value for the process parameter.

2. Enter the Parameter Description for the process parameter.
3. Enter the Minimum value for the process parameter.
4. Enter the Maximum value for the process parameter.
5. Enter the Units for the process parameter
List of Values
List Value: If the Parameter Type is List Value, then you can enter the list of values in the
detail section. This selection indicates that all possible values for this process parameter are
defined in a static table of entries.

2 RESOURCES
Resources are the assets you use to produce batches, including production equipment and
employee labor.
2.1 GENERIC RESOURCE

 Enter a Resource code to identify this resource. Required.
 Enter a brief Description of the resource. Required.
 Enter a Usage UOM (usually in hours) by which you measure the amount of time
used for processing this resource.
 Enter a Cost Component Class. A cost component class links this individual resource
to a unit of measure and allows you to establish costing parameters for the resource
in the Cost Management application.
 Click the check box Outside Processing if this is an outside processing resource

Capacity (Optional):
1. Enter the Minimum and Maximum amount per vessel capacity (maximum output a
resource can produce at one point of time) for this resource.
2. Enter the Capacity UOM for this resource. This is usually specified in mass or volume
not time.
3. Save your work.
Resource Classes: (Optional)
User can define resource classes using the Resource Classes window in OPM Process
Planning.
Navigate to OPM Process Planning > Capacity Planning > Setup > Resource Classes. Assign
the resource class to resource in Resources Window.

Entering Process Parameters

To enter the process parameters, Click on Process Parameters.
Parameters
1. Enter the Sequence number for the resource.

2. Enter the Process Parameter name & can be populated through the list of values or
by clicking Associated Parameters.

1. Enter the Target Value for the process parameter. Target value is the ideal setting
for the process being run.
2. Enter the Min Value for the process parameter. The minimum value is the lowest
acceptable value for a numeric type process parameter. Do not exceed the range
defined for the process parameter.
3. Enter the Max Value for the process parameter. The maximum value is the highest
4. Enter the units of measure for the process parameter in the Units field.
5. Save your work.
2.2 PLANT RESOURCES

To define a Plant resource, Navigate to Process Engineer > Set Up > Plant Resources.
1. Enter the Resource for which you are establishing available capacity parameters and
production costs when used in the designated organization (production).
2. Enter the Count. This is the number or quantity of the resource used in the specified
inventory organization for which you are defining production costs and usage
availability.
3. Enter the Planning Cost of this resource when used in the specified inventory
organization. It is used for reporting purposes only.
Capacity
1. Enter the Range for the resource's minimum and maximum amount per vessel
capacity unit at this inventory organization.
2. Enter the Ideal for the resource's optimum amount per vessel capacity unit at this
inventory
3. organization.
4. Enter the UOM by which the resource capacity is measured in this inventory
organization.
5. Save your work.

Process parameters for that resource can be viewed by clicking on process parameters
1. The Seq number for storing the process parameters in a unique sequence.
2. The Process Parameters name.
3. Edit the Target Value for the process parameter. This is the ideal setting for the
process being run.
4. Enter the Min Value for the process parameter. The minimum value is the lowest

5. Enter the Max Value for the process parameter. The maximum value is the highest
6. The Units field displays the unit of measure for a numeric type process parameter.
2.3 OSP RESOURCE

If a resource is used for outside processing following are the additional information
required.
 Click on the Outsource Processing check box

 Enter the service Item
 Enter the Cost structure e.g. PO Price or Resource Cost
3 ACTIVITIES
An Activity is an action performed during the manufacturing process, such as mixing or
heating.
Defining Activities
To define an Activity, Navigate to Process Engineer > Setup > Activities
1. Enter an Activity Code for the name of the activity. Activities are the components
that make up an operation.
2. Enter a brief Description of the activity.
3. Enter the cost Analysis Code.
4. Save the work.

4 PROCESS OPERATIONS
An operation is an ordered set of activities that have to be completed for a predetermined
step in a production batch, and includes specified resource requirements.
Defining Operations
To define Process Operations, Navigate to Process Engineer > Process Operation
1. Enter the Operation name.

2. Enter the Version number for this operation.
3. Enter a brief Description for Resource.
4. Enter a Valid from date as a validity rule for this operation. The default date is the
current system date.
5. Enter a Valid to date as a validity date for the expiration of this operation. If there is
no expiration date for this operation, leave the field blank.
6. Enter the Owner Organization for this Operation. A Description of the Owner
Organization displays.
7. Minimum Transfer Qty displays the minimum amount of material that must be
produced in a step at a specific production operation and resource before the next
operation can begin.
8. Enter a Process Qty UOM for this operation. (Mass or volume)
Activities
1. Enter an Activity required for this operation. A Description of this activity displays.
2. Enter the Activity Factor to specify the number of times the activity is performed in
this operation.

To change the operation status

1. Choose Change Status from the Actions menu.
2. Change the Current Status displayed by selecting a different Status from the Change
Status To list.
3. Click OK.

Assigning resources to Activities

To assign a resource to an activity click Resources. The Resource and its Description display.
Throughput
1. Enter the planned Process Quantity for the resource. The UOM entered on the
header displays. This is the unit of measure for the planned process quantity.
2. This value combined with the Usage quantity defines the usage rate.
3. Enter the planned resource Usage. This is typically expressed in hours.
4. Enter the UOM as the unit of measure for the resource.
Cost Information
1. Enter the Component Class code. The component class is set up in the Oracle
Process Manufacturing Cost Management application and defaults from the
Resource.

Navigation
OPM Financial>Setup>Cost Component Classes
Following window will appear
1. Enter the code to identify the Component Class

2. Enter a Description for the component class

3. Enter the Primary Component Class

4. Enter the Component Group (optional)
5. Enter Usage of the Component Class e.g. material, overhead, resource
6. Enter the Sort Sequence for the component class. It indicates the order in which
component classes displays on forms and reports.
7. The double brackets ([ ]) identify a descriptive flexfield. You can use these
descriptive flexfields to enter more information for each cost component class
8. Product Cost Calculation indicator lets you flag those component costs to be
excluded from the Cost Rollup process. Certain identifiable costs (for example,
transfer costs) are for specific ingredient items, and are not required to be rolled
up into the products. The valid values are:
 Include in Product Cost Calculation

 Exclude From Product Cost Calculation
 Valuation Option indicator lets you identify whether the component class must
be used for valuing inventory or not. The valid values are:
 Will be used for inventory valuation

 Will not be used for inventory valuation
 The valid values for Purchase Price Variance are:
 Include in Purchase Price Variance Calculation

 Exclude from Purchase Price Variance Calculation
9. Enter the Cost Analysis Code.

Scheduling Information
1. Enter the Plan Type to define the resource as Primary, Secondary or Auxiliary
2. Enter the Count as the number of resources needed for the activity entered. For
example, if two blenders are used for mixing, enter a 2 in the count.
3. Enter the Offset Interval as the time delay from the start of the activity to the point
where the resource is actually required.
4. Select the Scale Type as Proportional

5 PROCESS OPERATION CLASSES

Process operation classes can be defined to club similar operations.
Navigate to Process Engineer > Setup > Process Operation Classes
6 PROCESS ROUTINGS
A routing is a sequenced set of operations to perform to complete a production batch. The
operations are presented in a series of steps that organize these operations into an orderly
set of activities that have individual resources associated to them.
Entering Process Routing Details

To create Process Routing.
Navigate to Process Engineer > Process Routings.
1. Enter the code for the Routing.

2. Enter a Routing Version of the routing.
3. Return to this window to change status by selecting Change Status from the Actions
menu after entering all relevant information and saving the process routing with the
default Status of New. Depending on whether workflow is enabled, a different set of
statuses is available.
4. Enter a Routing Description that briefly describes the routing.
5. Enter a Class for the routing to identify how it is categorized. The Class Description
assigned to the class displays.
6. Enter the Valid from date for this routing. The default date is the current system
date. Required.

7. Enter a Valid to date for the expiration of this routing. If there is no expiration date
for this routing, then leave the field blank.
8. Enter the process Quantity for this routing. This is the total quantity of material for
the routing, and is used to scale individual step requirements.
9. Enter the process quantity UOM associated with this routing.
Routing Steps
1. Enter the Step number to associate with an operation in this routing. It is

recommended that the first number in this sequence be 10, the second 20, and so
forth. You can add intermediate steps between 10 and 20 at a later time.
2. Enter the code for the Operation performed in this routing.
3. Enter a Version number for the routing. The Description displays.
4. Enter the operation Step Quantity as the quantity of material associated with this
step. The UOM for the step quantity displays.
5. Min Transfer Qty is the minimum amount of material that must be produced in a
step at a specific production operation and resource before the next operation can
begin.
To change the routing status
1. Click to the Actions menu.
2. Choose Change Status from the menu.

3. Change the Current Status displayed by selecting a different Status from the Change
Status To list.
4. Click OK.
Once status is changed routing status will be changed accordingly and can be viewed on the
Process Routing Detail form.

7 PROCESS ROUTING CLASSES

Process routing classes are defined to club routing of same class. Navigate to Process
Engineer > Setup > Process Routing Classes.

8 FORMULAS
Formulas are lists of ingredients and products with their associated quantities and
processing instructions. Production batches are based on formulas defined in Product
Development.
To enter formula details, Navigate to Formulator > Formulas
1. Enter the Code for the Formula. (Concatenated item code)

2. Enter the Formula Version.
3. Enter a Description that briefly explains the formula.
4. Organization displays the name of the organization responsible for the formula. The
Organization Description assigned to the organization displays.
5. Enter the Owner of the formula. The Owner Description displays.
6. Select Scaling Allowed to indicate the formula allows scaling.
7. Enter Recipe Lot Number in the Comments tab.
Products
1. The Line number for each product listed displays. These fields cannot be edited.
2. Enter the Product Code for each item produced by this formula. If the formula code
entered is the same as an item code, then that item code displays as the default for
the first product line. A minimum of one product is required for a formula.
3. The Description of the product entered displays.
4. Enter Quantity of the product that this formula yields.
5. Enter the UOM for the quantity entered
6. Scale Type is Selected to be Proportional

7. Yield Type will be selected from list of values

8. Cost Allocation indicates how the cost of this item is allocated for financial purposes.
By-Products
1. The Line number for each byproduct listed displays. These fields cannot be edited.
2. Enter the By-Product code for byproduct items produced by this formula.
3. The Description of the byproduct entered displays. This defaults from the Item
Master table.
4. Enter the Quantity of the byproduct that this formula yields.
5. Enter the UOM for the quantity entered.

Ingredients
1. The Line number for each ingredient listed displays. These fields cannot be edited.
2. Enter the Ingredient code for each item required by this formula. A minimum of one
ingredient is required for a formula.
3. The Description of the ingredient entered displays. This defaults from the Item
Master table.
4. Enter Quantity of the ingredient that this formula requires. The quantity entered in
this field is the default standard quantity used for the recipe. It can be changed at
the recipe level.
5. Enter the UOM for the Quantity entered.

To change the formula status
1. Choose Change Status from the Actions menu.

2. Change the Current Status displayed by selecting a different status from the Change
Status To list.
3. Click OK. The Formula Details window displays the revised Status for the Formula.
9 RECIPES
Recipes standardize the structure of all information that describes production of one or
more products.
To enter recipe details, Navigate to Process Engineer > Recipes
1. Enter the code for the Recipe to be entered.

2. Enter a Version of the recipe.
3. Enter a Description for the recipe.
4. Enter the main Product for the formula associated with this recipe. If you enter a
new recipe, then enter the formula to fill this field automatically.
1. The Output Quantity displays the sum of the product quantities entered in the
formula. UOM is the unit of measure for the formula associated with this recipe.
2. Enter the Formula for the recipe. The formula Version displays.
Note:This field cannot be edited after you save this recipe. You cannot use an inactive
formula in a recipe.

3. Enter a Routing for the recipe. A routing can be added to an existing recipe. The
Version for the routing entered displays.
Plant/Laboratory
The following fields are display only:
4. Organization displays the Organization code that the process loss is being defined
for.
5. Organization Name displays a description of the plant or laboratory.
6. Type indicates whether this is a plant or a laboratory.
7. Process Loss displays the material that is lost through the process. This field is blank
if you did not enter a routing. You can override the default process loss.
8. Contiguous is selected if routings in this recipe must be run in one contiguous block
of time.
Step quantity regarding particular operations can also be viewed at recipe details window.
Quantities can be manually changed at each Step/Line on Routing lines.

To Edit Recipe Validity Rules:

Click on recipe Validity Rules. The following fields are display only:
1. Formula displays the formula used in the recipe with its Version and Description.
2. Routing displays the routing used in the recipe with the routing Version and
Description.
3. Return to this window to change status by selecting Change Status from the Actions
menu after entering all relevant information and saving the validity rule with the
default Status of New.

4. Enter the Organization. The Organization description displays.

5. Enter a Product in the formula for the validity rule. The product Description field
displays.
6. Enter the Preference number for the validity rule. When more than one formula can
be used to produce the same product, this field indicates the validity rule that must
be used first, second, third, and so forth. Preference defaults to 1.
7. Enter the Standard Quantity of product made with the formula. This does not
restrict quantities that can be produced with the formula.
8. UOM is the unit of measure for the standard quantity. You can enter and save a
different unit of measure.
9. Enter the Minimum quantity of product that can be made using the Formula.
Minimum defaults to 1.
10. Enter the Maximum quantity of product that can be made using the formula.
11. Enter From date as the date the validity rule becomes effective. The date must be
within the effective date for any routing associated to the recipe. Required.
12. Enter the To date as the date to stop using the validity rule. If an expiration date is
not defined for the validity rule, then this is an optional field and must be left blank.
13. Save the Window.
Recipe Step/Material Association:
The Recipe Step/Material Association window displays all items from the recipe formula and
lets you associate these items with specific routing steps.
Entering Recipe Organization Details:

Use the Recipe Organization Details window to display and, if necessary, override
information defined for specific operations and routings at the plant or laboratory level.
To enter recipe organization details:

1. Navigate to the Recipe Organization Details window. The Find Recipe Organization
Details window displays.
Attention: The first time you enter recipe organization details, click New.
Otherwise, enter the required information in the Find Recipe Organization
Details window.
2. Enter the Organization where you want to override information that is defined for
specific operations and routings. Required.
3. Click Find.
4. The following fields are display only:
 Organization indicates the code for the plant or laboratory that owns the recipe.
 Type displays Plant if the organization is a plant, or a Laboratory if the organization is
a laboratory.
 Organization Name displays the description assigned to the organization. This field
defaults to the entry from the Recipe Details window. Required.
 Planned Process Loss displays the loss of process material observed during
production of a batch using the recipe as a percentage. You can enter and save a
different planned process loss value for the recipe used in the organization
displayed. This value defaults to the theoretical process loss when no entry is made
on the Recipe Details window.
 Theoretical Process Loss displays the hypothetical loss of process material associated
to a routing. If no routing is associated to the recipe, this field is blank
Activities:

 Step indicates the step number associated with the listed operation. Steps
cannot be added or deleted here.
 Operation displays the operation associated with the step. The operation
Version and Description display.
 Activity displays the activity associated with the operation. The activity
Description displays
 Factor display the no of times an activity performed in the operation.
Capacity:
Version displays.
 Activity displays the activity associated with the operation. Activities cannot
be added or deleted here.
 Resources displays the resource associated to each displayed activity.
 Minimum Capacity shows the resource minimum capacity
 Maximum capacity shows the maximum output can be generated by
resource at one point of time.
 UOM displays the unit of measure for both Min Capacity and Max Capacity
entries.

Throughput:
Version displays.
 Activity displays the activity associated with the operation. Activities cannot
be added or deleted here.
 Resources displays the resource associated to each displayed activity
 Process Qty displays the total quantity of material for the step with its UOM.
 Usage displays the unit of the resource used to perform the activity on the
displayed step.

10 RECIPE APPROVAL
All recipes will be defined in the system in new status. Once all information relating to
recipe is entered, user will send the recipe for approval.
1. Click on the actions tab

2. Click on Change Status
User will select the Approved for General Use and enter the Ok button.

System generate a pop up to navigate to HTML page for sending recipe for approval.
User will open the HTML page
Following window will appear.
User will click on the submit button.

System will generate following pop up
Click on yes
Following pop up will appear
Upon clicking yes button recipe will be send for approval to the relevant approver.
User will go back to the application screen and will click on ok tab.
User can see the status of the recipe.

Recipe approval by relevant approver
Once recipe is sent for approval, approver will receive a notification for recipe approval.
User will open the notification. Following window will appear.

User can see the following information on this page.
 Recipe number
 Version
 Recipe description
 Formula
 Formula version
 Formula description
 Routing number
 Routing version
 Routing description
 Ingredients Quantity & UOM
 Operations
 Step material association
Approver will read all the e-record relevant to the recipe and will enter yes that he read
all the information’s. and the click on approve button.

Approver will enter the name and password and the click on sign.
Upon click on the sign button recipe will be approved.
Relevant person will recipe a notification of recipe approval.
User can open the recipe and can see the status.

Once recipe is approved user will change the status of the validity rules of the recipe.
1. Click on validity rules

2. Click on actions
3. Click on Change status

User will change the status “Approved for General Use” and click on ok.
Now recipe is available for general use.

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GHANI GROUP OF COMPANIES

(OPM PRODUCT DEVELOPMENT)

A. F. FERGUSON & CO.

Setting up Process Parameters

To define a Process Parameter,

Navigate to Process Engineer > Set Up > Process Parameters

1. Navigate to the Process Parameters window.

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1. Enter the Parameter Value for the process parameter.

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2.1 GENERIC RESOURCE

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Entering Process Parameters

1. Enter the Sequence number for the resource.

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2.2 PLANT RESOURCES

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2.3 OSP RESOURCE

 Click on the Outsource Processing check box

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To define Process Operations, Navigate to Process Engineer > Process Operation

1. Enter the Operation name.

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To change the operation status

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Assigning resources to Activities

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OPM Financial>Setup>Cost Component Classes

Following window will appear

1. Enter the code to identify the Component Class

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3. Enter the Primary Component Class

 Include in Product Cost Calculation

 Will be used for inventory valuation

 The valid values for Purchase Price Variance are:

 Include in Purchase Price Variance Calculation

9. Enter the Cost Analysis Code.

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5 PROCESS OPERATION CLASSES

Navigate to Process Engineer > Setup > Process Operation Classes

Entering Process Routing Details

Navigate to Process Engineer > Process Routings.

1. Enter the code for the Routing.

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1. Enter the Step number to associate with an operation in this routing. It is

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7 PROCESS ROUTING CLASSES

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To enter formula details, Navigate to Formulator > Formulas

1. Enter the Code for the Formula. (Concatenated item code)

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7. Yield Type will be selected from list of values

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To change the formula status

1. Choose Change Status from the Actions menu.

To enter recipe details, Navigate to Process Engineer > Recipes

1. Enter the code for the Recipe to be entered.

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