The relationship between Oracle Process Manufacturing and Advanced Supply Chain Planning (ASCP) involves data setup in OPM, the use of this data in ASCP for planning, and the flow of suggestions from ASCP to OPM. This chapter considers data setup, use, and feedback.
This chapter covers the following topics:
Setting up data in OPM includes the following :
Defining Firmed Batches
Defining Minimum Transfer Quantity Requirements
Defining Resource Exception Messages
Considering Post Processing Leadtime for Purchased Items
Considering the Leadtime Calculator
Regenerating Targeted Resource Availability
Planning for Bottleneck Resources
Using data in ASCP includes the following:
Consuming Forecasts in Advanced Supply Chain Planning
Initiating Resource Simulation
Sending feedback from ASCP to OPM includes the following:
Understanding Planned Order Detail Feedback
Implementing ASCP Planning Suggestions in OPM
Selecting Validity Rules upon Batch Creation
OPM uses the APS planning capabilities by exchanging the data established in OPM. This section discusses the changes in the OPM data collection process.
The topic focuses on the recipe related data element extraction and calendar data extraction, including the process to capture:
Step dependency data for implementing complex routes.
Minimum Transfer Quantity for products and associated hardlinks data.
Resource capacity data for APS to calculate operation charges.
Sequence dependent setup data.
Secondary resources, resource instances, resource availability, and resource instance availability data for APS to schedule these resources.
Raw material or intermediates are processed through a set of operations, also referred to as routing steps. These steps are sequenced in the order of the manufacturing requirements. Such sequence of execution of the steps is reflected in OPM by utilizing the step dependency functionality, which allows modeling of various types of dependencies among the steps of a route. The resultant route is referred to as a complex route.
The step dependency data is transferred to the APS engine to consider complex routes. The data is transferred using bulk collections, which improves the performance. As a result of complex routes, the product can be yielded at any step. Data collection is modified to transfer the routing step number where the product is yielded.
The functionality provides the ability to dynamically calculate the step quantity based on the materials coming into the step. The data collection process supplies all the data to perform the calculation. The recipe definition indicates which recipes have this calculation executed and which use the step quantities passed in the collection.
The nature of manufacturing process and the materials involved it calls for processing the material completely till all the products are yielded, without permitting any time gap between operations. This is addressed by the provision of contiguous operations and "hardlinks", which allow specified breaks (can be specified to be zero also). Such a break can be specified between operations or between yield point of a product and its consuming operation.
Minimum Transfer Quantity (MTQ) and hardlinks data is transferred to the APS engine to consider MTQ. The collection program transfers the following information to APS for it to consider MTQ and hardlinks:
Minimum Transfer Quantity
Minimum Delay
Maximum Delay
The manufacturing process may also be constrained by the physical capacity of the resources involved in the operations. Whenever such capacity constrained resources are required to process material more than their capacities, they are required to repeat the task multiple times. This is referred to as Operation Charges.
The operation charges data is transferred to the APS engine to calculate charges for critical resources. APS calculates charge information for resources marked as critical and having scale type as "Fixed By Charge." The collection program transfers the following information to APS:
Resource Min Capacity
Resource Max Capacity
Status of the Calculate Charges option
Schedule Scale Type
You can override the resource minimum and maximum capacity at the recipe level. If these values are overridden, then the updated values are passed to APS during the collection process.
The operation charge data is transferred to APS using bulk collections, which improves the performance.
Note: You cannot have multiple instances of a chargeable resource. The resource count must be one.
The sequence in which manufacturing orders are executed can affect the performance of the organization. Executing changeovers when switching from one product to another can consume valuable manufacturing time. Reducing these changeovers is essential to process manufacturers.
The sequence dependency data is transferred to APS. The collection process requires the transfer of the following information to APS:
Sequence Id
Sequence Number
Firm Type
Setup_id
The sequence dependency data is transferred to APS using bulk collections to improve performance.
A new concurrent program is created to generate the sequence dependent ID in batches and FPOs. This procedure is called upon during batch manipulation.
Substitute items are available to the Oracle Advanced Planning and Scheduling (APS) application as replacement items with the corresponding effective end dates for original as well as substitute items. APS uses the substitute item, when one exists, from the effective date until the end date specified. If there is no longer an effective substitute, then APS reverts to using the original item. In the collection and planners workbench, substitute items are displayed with their effective dates. The information is also used during Available to Promise/Capable to Promise (ATP/CTP) computations to ensure the use of appropriate items.
If substitution lists have overlapping effective date periods, then the list with the lowest number in the Preference field is used.
The current system date is: 01-FEB-2005. Item A has two effective item substitution lists: List 1 and List 2 with the following information:
| Item Substitution List 1 | Item Substitution List 2 | |
| Item | B | C |
| Effective Start Date | 01-MAR-2005 | 15-MAR-2005 |
| Effective End Date | 31-MAR-2005 | 30-APR-2005 (or null) |
| Preference | 1 | 2 |
For 20-MAR-2005, Item B from Item Substitution List 1 is used because it has a higher preference. A preference of 1 is higher than a preference of 2.
Data setup can include defining firmed batches. Prior to initiating an Oracle Advanced Supply Chain Planning (ASCP) Workbench run, you can flag batches to prevent them from being considered for rescheduling or cancellation. Certain batches can be committed to a shop floor for many reasons including availability of a raw material soon to expire or the completion of an involved and lengthy setup activity.
The batch is flagged as firmed through the Batch window under the Production Supervisor responsibility. ASCP interprets the checked Firmed flag of the batch and ensures that changes are not to be made to them. Once ASCP knows that there is a firmed batch, the dates for the firmed batch remain unchanged.
Refer to the Oracle Process Manufacturing Process Execution User's Guide for details on creating a batch.
Navigate to the Batch window in the Production Supervisor responsibility.
Select the Firmed option.
Save the batch.
Perform background collection.
Navigate to the Supply Chain Planner Workbench.
Launch a plan.
Navigate to the Supply/Demand window for the given plan. Note the Firm flag is checked for the appropriate items and that the remaining batches are rescheduled around the firmed batch.
Data setup can include defining minimum transfer quantity requirements. Prior to initiating an Oracle Advanced Supply Chain Planning (ASCP) Workbench run, you can define Minimum Transfer Quantity (MTQ) requirements to efficiently plan and schedule OPM production batches that have a minimum leadtime between operations.
MTQ is the minimum amount of material that must be processed at a given production operation before the material can be transferred to the next operation.
Let's assume that the MTQ is defined at the routing step level. If step quantity is defined as 100L for an hour duration but you want to start the next operation after a half hour, then you would enter 50 as the MTQ. This quantity is converted into the correct proportion of the product quantity and UOM of the recipe.
By defining MTQ requirements, a subsequent operation can begin before its previous operation is completed when a sufficient quantity of material is processed and available for transfer. MTQ enables the reduction of overall leadtimes between operations.
Navigate to the Operation Details window under the Process Engineer responsibility.
Enter operation information.
Type Minimum Transfer Qty in the header section of the window.
Save the operation.
Note: The Minimum Transfer Qty value defaults from the Operation Details window to the Routing Details and Routing Step Line windows.
Define a formula with intermediate ingredient.
Define a routing with multiple steps.
Define a recipe and validity rules with the defined formula and routing.
Type Minimum Transfer Qty on the Operation Details window.
Create demands for larger quantities for the final finished good so that the quantity to be processed at each step is much larger than the MTQ.
Perform data collection.
Run plan.
Verify operation times. The start time of the subsequent step is offset by the time greater than or equal to the time required to manufacture the MTQ at the previous step. Stagger the steps; do not schedule them sequentially.
Type Minimum Transfer Qty on the Routing Details window for the last step of the routing used for the intermediate ingredient. After running the plan, scheduling is staggered between the intermediate batch and the final finished batch.
In a process manufacturing environment, certain known procedures are in accordance with Good Manufacturing Practices and affect the OPM Inventory, OPM Quality Management and Oracle Advanced Supply Chain Planning (ASCP) applications.
Purchased items are declared as inventory upon receipt in order to fulfill labeling and inspection requirements and ensure the traceability of goods received.
Received goods are placed under quarantine while inspection sampling determines the acceptability of this material. When a lot that is received into inventory requires inspection, it is placed onhold until released by quality management personnel. This quality hold can be modeled as a standard leadtime that defaults for all lots of an item. A secure user with the proper responsibility can change the release date for a lot depending on the actual length of the inspection process. If an inspection leadtime is not initially defined for an item, then a lot release date can still be entered manually.
ASCP recognizes that material of a lot is available for use after the hold release date. By taking a fixed leadtime into account without recommending new demand requests, the future availability of these lots is planned. For a lot that is received into inventory, ASCP recognizes that the lot is not available until after the hold release date. ASCP considers a hold release date so that the availability of onhold lots can be planned and no recommendations for immediate use of the inventory are suggested.
Data setup can include establishing leadtimes. ASCP data collection routines consider onhold inventory to be material in receiving. Onhold inventory are items that have a hold release date defined in the Lot Master window of the Inventory application. Through item synchronization, the Post Processing Leadtime field of the Oracle Inventory Item Master is populated.
While computing the timing of purchasing suggestions, ASCP uses the Post Processing Leadtime value of the Oracle Inventory Item Master.
For example, if a requirement for an item exceeds the onhand inventory, then ASCP will make a replenishment suggestion to fill that requirement even when ample onhold inventory exists. Onhold inventory might exist but is not considered usable by ASCP until after its Hold Days value is exceeded.
ASCP considers a lot that has a Hold Release Date greater than the data extraction date to be a lot in receiving. The Hold Release Date is calculated based on the Hold Days value of the OPM Item master or is manually entered through the Lot/Sublot window. ASCP uses this Hold Release Date as the new schedule date:
Lot Availability Date = Hold Release Date
Prior to the Hold Release Date, ASCP does not consider the lot usable regardless of lot status. After the Hold Release Date, ASCP makes use of the lots with a nettable status.
Data setup can include entering parameters for the Leadtime Calculator. Leadtime Calculator is a processing engine that automatically computes fixed and variable leadtimes by considering the route that is most likely to be used in the production of the product.
Initiated as a submitted request through the application, the Leadtime Calculator can be run for the following:
One or all items
One or all organizations
Once generated, the calculated leadtimes are automatically saved to the variable and fixed leadtime fields in the Oracle Inventory item master. As the leadtime attributes are populated automatically, this eliminates having to calculate and manually enter these leadtime values. Keep in mind, however, that if you have manually entered leadtime values for specific item organization combinations and want to keep these values, then do not run the Leadtime Calculator for the item organization combinations as the values will be overwritten.
The Leadtime Calculator references each of the following OPM business objects: resource, activity, operation, routing, and formula.
The Leadtime Calculator processing engine makes use of OPM recipe and routing data; synchronizes logic with Advanced Supply Chain Planning (ASCP); computes and stores offset percentages; distributes the calculated leadtime values as the defined workday standard; automatically updates item attributes with the leadtime values.
Based on the validity rule with the highest preference, the preferred route for a given product is selected by the calculator without user intervention. OPM uses the standard quantity from the recipe validity rule as its base. The operations in the route provide the parameters for calculating the fixed and variable leadtimes of an item.
An offset percentage is the percentage in time at which the material transaction, that is the ingredient consumption or the product yield, is expected to occur. Offset percentages of ingredient consumption and product yield are calculated by considering the duration of a batch of standard quantity and the material transaction times. Each ingredient is planned at the beginning of its operation as per the material step association. The yield of each product, coproduct, or byproduct is planned at the completion of each operation as per the material step association. Release type validation is enforced.
As an industry standard, processing leadtime is computed as the total integer days required to manufacture one leadtime lot size of an item. As such, all leadtimes calculated by the Leadtime Calculator are converted into days based on the plant's defined workday.
After the processing engine computes the leadtimes, the calculated values are automatically saved as item attributes of the items in the specified inventory organizations.
Refer to Oracle Advanced Supply Chain Planning User's Guide for setting up leadtime calculators.
Data setup can include planning for bottleneck resources. A bottleneck resource is a resource whose throughput rate is less than the throughput rate needed to meet the demand placed upon it. A bottleneck resource is the most constrained resource that is used in production. A bottleneck machine or work center exists where jobs are processed at a rate slower than the rate for which they are demanded. In general, it is more effective to resolve the most constrained resource than to resolve the least constrained resource.
By enabling the definition of bottleneck resources, you can constrain the heavily demanded resource and still collect resource requirements for all other resources. As such, you can focus on key resources and allow them to define the scheduling of production orders.
Resources are associated to an organization and linked to group resources through the Resource Information window. The bottleneck resource is derived from this group resource. Refer to Oracle Advanced Supply Chain Planning User's Guide for details.
Using data in Advanced Supply Chain Planning (ASCP) can include the consumption of forecasts. Forecast consumption occurs as part of the ASCP, not the data collection process.
Forecasts are defined and subsequently input to the ASCP planning engine as demand independent of sales order collection. Upon input to the planning engine, forecasts are available for consumption within the planning process.
Forecasts are associated to a forecast set, which is a logical grouping of like forecasts. A forecast set is mandatory for ASCP forecast consumption. A separate forecast set must be defined for each inventory organization.
Forecast sets allow for the definition of consumption requirements and are introduced to the ASCP planning engine directly. Once the forecast set is input to the ASCP planning engine, the following consumption information is available to ASCP:
Whether the forecast is be consumed or not
How far back or how far into the future in terms of days ASCP looks to locate a sales order to consume the forecast.
Note: Sales orders originate exclusively from Oracle Order Management tables allowing for Net Change data collection. The collection routine recognizes both discrete and process instances associated with Oracle Order Management. Currently, sales orders are not collected from OPM Order Fulfillment.
Using data in Advanced Supply Chain Planning (ASCP) can include initiating resource simulation. Once you receive information from an ASCP Workbench run, you can initiate test runs through the workbench for modifying resource capacity. You can set, add, or reduce resource capacity over a specified time frame. Resource simulations enable you to anticipate potential changes in resource capacity and plan in preparation of them.
From the Update Resource region of the Resource Availability window, you can initiate the following changes and subsequently launch a plan simulation:
Add Capacity - Selecting this option from the Update Mode field enables you to increase the number of resources, which is the capacity count, for a particular shift over a period of time. In doing this, the following fields are enabled: From Date, To Date, Shift Number, From Time, To Time, Capacity Units. The number of resources entered in the Capacity Units field is added to the resource capacity. The resource capacity is applicable only for the resource for which the resource availability is shown.
Take Resource A, which for example purposes is assumed to be defined on the OPM Plant Resource window with a Capacity Unit value of 4. On the Resource Availability window, if 25 is entered in the Capacity Units field for Resource A, then the resource availability hours are calculated based on 29 units of Resource A being available.
Reduce Capacity - Selecting this option from the Update Mode field enables you to reduce the number of resources for a particular shift over a period of time. In doing this, the following fields are enabled: From Date, To Date, Shift Number, From Time, To Time, Capacity Units. The number of resources entered in the Capacity Units field is deleted from the resource capacity. The resource capacity is applicable only for the resource for which the resource availability is shown.
Take Resource B, which for example purposes is assumed to be defined on the OPM Plant Resource window with a Capacity Unit value of 4. On the Resource Availability window, if 1 is entered in the Capacity Units field for Resource A, then the resource availability hours are calculated based on 3 units of Resource B being available.
Set Capacity - Selecting this option from the Update Mode field enables you to set the number of resources for a particular shift over a period of time. In doing this, the following fields are enabled: From Date, To Date, Shift Number, From Time, To Time, Capacity Units. The number of resources entered in the Capacity Units field is taken as the resource capacity. The resource capacity is applicable only for the resource for which the resource availability is shown.
Take Resource C, which for example purposes is assumed to be defined on the OPM Plant Resource window with a Capacity Unit value of 4. On the Resource Availability window, if 15 is entered in the Capacity Units field for Resource A, then the resource availability hours are calculated based on 15 units of Resource B being available.
Add Day - Selecting this option from the Update Mode field enables you to add a day to the calendar. In doing this, the following fields are enabled: From Date, Shift Number, Capacity Units. You can only add a day on a non-work day.
After a non-working day is specified and the planner is launched, the appropriate date, resource capacity, and shift listed in the Resource Availability window displays.
Delete Day - Selecting this option from the Update Mode field enables you to remove a day from the calendar. In doing this, the following field is enabled: From Date. As no validation is done on the date, you can remove a work day or a non-work day.
Once you have made changes at the resource level, you can launch a new plan. Either a completely new plan or a net change replan can be launched. Net change replan simulations enable you to update a plan by planning only for those items that have been previously modified in the workbench. The following modes exist for running a net change replan:
Batch Replan - In batch mode, direct database interaction is executed. As such, your changes take effect at the database level. When one user is initiating the batch replan simulation, another user can access this revised plan.
Online planner - In online mode, database interaction is minimized. With an online session all planner information is loaded into memory, where you can initiate plan modifications and analyze the results without initiating direct hits against the database. The results of the plan are available only to the user initiating the changes.
Oracle Process Manufacturing (OPM) is a source for organization related information for Oracle Advanced Supply Chain Planning and Scheduling (ASCP/APS) to perform the advanced material and capacity planning. The ASCP planning you perform results in suggestions for the process items, organizations. The suggestions related to production batches in OPM, particularly the new batch creation and the rescheduling of existing batches, are implemented in such a way that all the details that are generated in APS are considered in OPM. ASCP is enhanced to consider the OPM charge, sequence dependency, resource instance level planning, and the alternate resource planning for reschedule suggestion.
In working with complete document detail level information, details of the planned production orders are synchronized from ASCP through the existing integration mechanism and transferred to OPM Process Execution in keeping with Process Execution rules. As such, batch and firm planned orders converted from these planned orders are consistent with ASCP planning, and they honor capacity constraints. The transferred information includes:
Complex Routing – continuous operations
Inter-Routing Hardlinks with MTQ
Charges
Sequence Dependent Setups and Usage
Alternate Resources
Resource Instances
In having full access to the planned order details, OPM considers resource availability and capacity constraints while making full use of the planning computations made in ASCP.
In working with the application, the procedure to implement the ASCP planned production orders remains unchanged. Review the suggestions generated by ASCP and release them from the planner's workbench. Review these suggestions in OPM through the APS New Batch window or APS Reschedule Batch windows. Upon executing these suggestions, OPM batches are created or rescheduled.
Complex Routes
The step dependencies are enforced by ASCP. The batch steps are scheduled by ASCP and supported by the feedback. The batch step dependencies are be affected by ASCP. The material association to a batch or batch step is also included as part of the feedback, but the details from ASCP are not used. If a material is associated to a step, then the feedback uses the step planned start date for ingredients or step planned completion date for products and byproducts. Material not associated to a batch step uses the batch planned start date for ingredients or batch planned completion date for products and byproducts. The scheduling of the activities is based on the sequence number developed for the operations where more than one activity exists. The activity and resource offsets are not applied by ASCP, as the engine considers activities to be sequential. The offset is used to order activities, but not in scheduling. A charge applies a slant to the step dependencies. If the dependencies are set as "apply to charge", then the dependency is placed on the charge, not the step.
MTQ with Hardlinks
The Minimum Transfer Quantity (MTQ) functionality includes a restriction on the gap between the point in time that the MTQ has been yielded for the item and the start of the next routing involving the item. The gap is defined with a minimum and maximum value based in the "TIME" unit of measure for Hour, calendar time. When calculating the gap, the minimum value causes a gap to exist and the maximum value limits the duration of the gap between the routing and the MTQ yield point. This MTQ calculation is added for all products of a recipe and batch. These values are reported as part of the data collection and used by the APS engine for planning purposes. The feedback does not have any direct relationship with MTQ and hardlinks. It affects the batch-to-batch relationships, but has no direct effect on an individual batch with regards to feedback.
MTQ includes the coproducts when it is recorded. When a coproduct is yielded from a batch step, the material is transferred to another routing as an intermediate ingredient. The process that yields the item yields a partial amount before the next routing can start. The MTQ value is recorded for any product of a recipe or batch when required. This does not include byproducts. These values are not reported during the data collection process for both recipes and batches and used by APS engine for planning purpose. The feedback does not have any direct relationship with coproduct and MTQ.
Charges
Charges are calculated as part of a batch, but the details of these charges are not recorded. The APS engine will recalculate the charges for an activity resource, which is sent back to OPM. Only one activity per operation is considered for charges. The number of charges is based on the step quantity and the maximum capacity of a resource in that activity. ASQC, if defined, is used to define the step quantity. The capacity constrained resource will only have a count of 1. The step dependency, if defined, is applied to the charges. All resources defined as "scale by charge" are scheduled in that way even if not constrained. If a resource is not scaled by charge, but part of the simultaneous group, then it is not scaled with the other chargeable resources.
Sequence Dependent Setups and Usage
When different products are produced using the same resource, you may need special setup tasks depending on the sequence in which the products are produced. The ASCP engine takes the definitions in the routings and batches for the sequence dependencies and applies them in the appropriate situations. When these situations occur for resources, a new activity is created to include the additional usage for these resources. The sequence dependent usage occurs before the first activity in the step. OPM detailed feedback implements the sequence dependent usage occurred for sequence dependent setups in case of planned and rescheduled suggestions. The sequence dependent usage resource transactions provided by APS are also implemented.
Sequence Dependencies
When there is a sequence dependency, it affects those resources defined at the instance level and as such all of the resource usage is down to the instance level for the resource. ASCP reports sequence dependency usage as on the activity or simultaneous group sequenced before the cause of the transition. In OPM, the usage is incorporated into the existing activity that is marked as sequence dependent. The usage is applied to the resource where the transition occurred and is recorded in the sequence dependent usage column in the batch step resource. The planned start date of the activity includes the sequence dependent usage, whereas the planned start date of the resource does not.
Alternate Resources
The utilization of an alternate resource functions similar to a planned order. When a planned order is converted into a batch or FPO, it is created as a batch and then adjusted for any modifications from ASCP. The process is the same for an existing batch where an alternate resource is selected. The details from the original resource are used, except for the usage. The usage is modified based on the alternate resource definition.
Resource Instances
If a resource is defined to have instances, ASCP assigns them in specific cases. If a resource is defined to be part of an operation that is considered for sequence dependent step, then the instances are assigned to the resource. In all cases of sequence dependencies, resource instance is assigned. This lets you identify dependencies. The instances are assigned in the resource transactions and viewed from only there. The definition of charges or sequence dependencies will let only one instance to be used for a resource as a restriction to the ASCP planning process. Only in a situation where the resource is not involved in these functions is there a chance for more than one instance to be assigned. The resource in the routing must have a count greater than one to have more than one instance. OPM detailed feedback routine recognizes the resource transaction detail for planned and rescheduled batches. While implementing the details, if resource transactions and resource instance transactions for the same resource for an activity are fed back from APS, then resource level transactions are ignored.
ASCP suggestions for production batches consist of the following:
Create a new batch
Reschedule an existing batch
Cancel an existing batch
For the Create and Reschedule suggestions, the ASCP generated details of the batch are transferred to OPM. Both material and resource transactions are transferred to OPM.
Cancel batch requires no additional consideration because once canceled, batch details do not require synchronization between ASCP and OPM.
For a planned production batch, ASCP generates planned details considering the production constraints. These planned details include the following:
Material transactions
Resource transactions
These details are based on the OPM formula and routing, which is chosen based on the preferred validity rule for the planned production batch. Let us take a closer look at both material and resource transactions for a newly suggested batch and an existing batch.
ASCP suggests the creation of new batches. Synchronization of material transactions between ASCP and OPM centers around three crucial fields:
Item
Date
Quantity
If a batch is created in OPM from a recipe that is used by ASCP in making a planning suggestion and no change to the recipe's formula is made between batch creation in OPM and plan generation in ASCP, then the items and quantities of the batch created in OPM and the batch suggestion created in ASCP are the same.
If an attempt is made in OPM to create an ASCP suggested batch, then subject to OPM date specific validation, then the OPM Process Execution schema is updated with the ASCP generated dates. If, for example, an ASCP batch creation date suggestion falls upon a date within a closed inventory period, then the batch is not created in OPM.
If upon OPM batch creation, you choose a different recipe that has a different formula or routing from the one that ASCP suggested, then the batch details are not synchronized from ASCP. In this scenario, the OPM Process Execution batch creation algorithm is used to create the batch.
If a OPM recipe related change is made after the data extraction on which the ASCP plan is based, then detail scheduled feedback does not happen. Material transactions are generated based on the OPM material types and step associations in the routing. The new batch is implemented using the updated OPM formula and routing.
The detailed feedback from ASCP to Process Execution not only includes routings, operations, activities, and resources but the constraints under which they operate: shop calendars and resource availability. Upon accepting the detailed feedback from ASCP, Process Execution resource transactions are synchronized with the ASCP generated start and end dates and its calculations.
Differences in the way that ASCP and OPM handle resource transactions follow:
Unconstrained and Constrained Planning - OPM users can use unconstrained, constrained, or optimized planning in ASCP. When a constrained or optimized plan is executed, the feedback details are synchronized to OPM. When an unconstrained plan is executed, the feedback details from ASCP are not used; the default OPM Process Execution calculations are used.
Daily Bucket Level Details - As ASCP bring back details to the daily bucket level, the detail feedback suggestions are provided in the daily scheduling and planning bucket.
Automatic Step Quantity Calculations (ASQC) - OPM Process Execution uses step quantities, which are automatically calculated based on the ingredients in the formula and routing, to determine resource usage.
Activity and Resource Offsets - OPM allows for the definition of offsets between activities and between resources in activities. ASCP does not consider offsets when calculating the timing of resource usage. ASCP does consider prior and next minimum transfer quantity when calculating resource and activity scheduling.
Primary and Auxiliary Resources - OPM considers differences in resource usage. ASCP uses maximum usage time only. For example, if some resources are defined as working for eight hours and other resources defined as working for four hours, then ASCP calculates the resource usage as eight hours. As this could have costing implications, OPM ignores ASCP usage time and retains its resource usage.
Alternate Resource - In performing the detailed capacity planning, ASCP can use an alternate resource. Upon accepting the detailed feedback, OPM is updated with the transactions for the alternate resource and reflects its timing and usage.
In summary, when batch details are synchronized from ASCP, OPM batches reflect the resource scheduling calculated by ASCP.
If any OPM resource change is made after the data extraction on which the ASCP plan is based, then the ASCP constrained based plan is invalidated and the new batch is implemented using default OPM Process Execution calculations. A warning message displays, which notifies you of the ASCP plan invalidation.
The resource changes that will invalidate an ASCP plan for a new batch include the following:
Routing changes - including addition or deletion of a step, changes to operations, changes to the sequence of steps.
Operation changes - including addition or deletion of activities, changes to minimum transfer quantity.
Activity changes - including addition or deletion of resources, changes to throughput speeds.
Resource changes - including changes to the counts.
ASCP suggests rescheduling of existing batches, which have existing material and resource transactions in OPM Process Execution.
The item, quantity, and transaction date of the existing OPM batch are updated to match the item quantity and transaction dates suggested by ASCP.
Differences in the way that ASCP and OPM handle material transactions follow:
Consolidated Transaction for a Multiple Transaction Item - OPM Process Execution can accommodate multiple transactions for a given item lot combination in a batch. These multiple transactions are created when an item is allocated to a lot many times. ASCP does not handle multiple transactions for an item. Instead ASCP consolidates multiple ingredient transactions to one ingredient transaction and multiple product transactions to one product transaction and applies a transaction date as follows:
Earliest transaction date applied for an ingredient
Latest transaction date applied for a product, coproduct, or byproduct
When a batch is rescheduled from ASCP, multiple transactions for an ingredient or product are consolidated to the one transaction and reflect the earliest or latest transaction date, respectively.
Product Yield and Last Step - OPM Process Execution allows for a product to be yielded at an intermediate step. As such, when an OPM batch having product yielded at an intermediate step is rescheduled by ASCP, the date and time of the material transaction associated with this intermediate step is assigned the date and time of the last step of the routing.
ASCP suggests rescheduling of existing batches, which have existing resource transactions in OPM Process Execution.
The resource transactions of an existing OPM batch are updated to match the resource transactions suggested by ASCP.
The difference in the way that ASCP and OPM handle resource transactions follows:
If an OPM material or resource change is made after the data extraction on which the ASCP plan is based, then the ASCP contrained based plan is invalidated and the reschedule process is not initiated. The reschedule suggestions are not implemented. The changes that will invalidate an ASCP plan for an existing batch include the following:
Batch status changes
Step status changes
Incremental completion
Converting a firm planned order to a batch
Once you receive information back from an ASCP Planner Workbench run, you can view the reschedule suggestions in OPM. You can view this information on the Reschedule Update window.
To reschedule existing batches
Navigate to the Reschedule Update window. The Organizations page displays.
Select the context organization from the Organizations window.
Select the Group ID whose suggestions you want to approve. The Group ID displays when you select a group of suggestions you want to release from the ASCP Planner Workbench run. The list contains the date and the remaining suggestions associated with the group ID.
Creation Date is the date that the group ID is generated from the ASCP Planner Workbench run. When you select the Group ID, the date displays.
Update Details
Click the Select check box to select the batches/FPOs you want to approve or reject.
The following fields display for each suggested batch:
Batch/FPO displays the batch or FPO number.
Old Plan Start Time is the original planned start date and time.
New Plan Start Time is the new planned start date and time.
Old Plan End Time is the original planned end date and time.
New Plan End Time is the new planned end date and time.
Select the Update Offset if you want to update the batch step offset interval suggested by APS to be written into OPM batches.
Master Batch
If a batch or FPO has a master batch, then following fields display for the master batch:
Recipe is the code of the formula on which the production batch is based.
Formula is the code of the formula on which the production batch is based.
Routing is the code of the routing on which the production batch is used.
Product is the code of the primary product produced by the batch.
Planned Quantity is the planned quantity of the primary product.
Doc Type displays as Batch or FPO.
Select Reject if you want to reject the suggestions for creating new batches/FPOs.
Select Reschedule to reschedule a batch.
Select Cancel to cancel and exit the window without taking any action.
Once you receive suggestions back from an Oracle Applications ASCP Planner Workbench run, you can view the cancellation suggestions in OPM and accept or reject the suggestions. Rejecting the cancellation suggestions keeps the batch/FPO, as originally scheduled. You can view this information on the Batch Cancellations window.
To accept or reject cancellation suggestions
Navigate to the Batch Cancellations window.
2. Select the context organization from the Organizations window.
3. Select the Group ID whose cancellation suggestions you want to cancel and reject. The Group ID displays when you select a group of suggestions you want to release from the ASCP Planner Workbench run. The list contains the date and the remaining suggestions associated with the group ID.
4. Creation Date is the date that the group ID is generated from the ASCP Planner Workbench run. When you select the Group ID, the date displays.
Update Details
Click the Select check box to select the suggested batches/ FPOs cancellations you want to reject or cancel.
The following fields display for each suggested batch cancellation:
Batch / FPO displays the batch or FPO number.
Old Plan Start Time is the original planned start date and time.
New Plan Start Time is the new planned start date and time.
Old Plan End Time is the original planned end date and time.
New Plan End Time is the new planned end date and time.
Select the Update Offset if you want to update the batch step offset interval suggested by APS to be written into OPM batches.
Master Batch
If a batch or FPO has a master batch, then following fields display for the master batch:
Recipe is the code of the formula on which the production batch is based.
Formula is the code of the formula on which the production batch is based.
Routing is the code of the routing on which the production batch is used.
Product is the code of the primary product produced by the batch.
Planned Quantity is the planned quantity of the primary product.
Doc Type displays as Batch or FPO.
Select Reject if you want to reject cancellation of the batches/FPOs. The FPOs or batches remain scheduled.
Select Cancel Batch if you want to cancel the batches/FPOs from OPM production.
Select Cancel to cancel and exit the window without taking any action.
Once you receive suggestions back from an Oracle Applications ASCP Planner Workbench run, you can view the new batch suggestions in OPM and convert them into OPM production batches or FPOs. You view this information on the Imported Batches window.
To schedule new batches
Navigate to the New Batch window
Select the context organization from the Organizations window.
Select the Group ID whose suggestions you want to approve. The Group ID displays when you select a group of suggestions you want to release from the ASCP Planner Workbench run. The list contains the date and the remaining suggestions associated with the group ID.
Creation Date is the date that the group ID is generated from the ASCP Planner Workbench run. When you select the Group ID, the date displays.
Select Approve as Batch, Firm Planned Order, or Reject.
Order Details
The following fields display for a suggested batch:
Product is the code of the primary product produced by the batch.
Batch/FPO is the batch or FPO number.
Planned Qty is the planned quantity of the primary product.
UOM is the unit of measure in which the primary product is produced.
Start Date is the start of the batch.
End Date is the end date of the batch.
Select the Update Offset if you want to update the batch step offset interval suggested by APS to be written into OPM batches.
Master Batch
If a batch or FPO has a master batch, then the following fields display for the master batch:
Recipe is the code of the formula on which the production batch is based.
Formula is the code of the formula on which the production batch is based.
Routing is the code of the routing on which the production batch is used.
Product Description is a brief description of the primary product produced by the batch.
Click Reject if you want to reject the suggestions for creating new batches/FPOs.
Click Convert to convert the imported batches into OPM production batches or FPOs. After clicking Convert, the OPM Process Execution APIs create new batches/FPOs and you may be prompted for more data input based on your setup.
Click Cancel to cancel and exit the window without taking any action.