An environment where you open a final assembly order to assemble items per customers order. Assemble-to-order is also an item attribute that you can apply to standard, model, and option class items.
assembly scrap
A process which allows you to scrap both scheduled and unscheduled flow assemblies from any flow operation. Components, their associated costs, and all labor and machine resources used at all events prior to the scrap line operation are automatically backflushed.
ATO
Seeassemble-to-order.
B
basis
Indicates whether the component quantity is required per item or per lot.
C
cumulative yield
Product of the yields at each operation, process, or event on a flow line.
D
dual card kanban
A demand pull signal that uses a move and produce communication method. Generally, move cards are collected and when the produce lot size is reached, the produce card is used to create the replenishment. This procedure is generally used when a minimum order quantity is required as a result of long set up times or economic order cost.
E
efficiency
Productivity measure that focuses on actual performance against a standard. Expressed in a percentage figure, it is calculated by dividing actual resource time charged to a task by the standard resource requirements for the same task.
elapsed time
The clock time between start and completion.
event
An event is an identifiable point in time among a set of related activities. In Flow Manufacturing, events are the lowest level of activities in a flow routing. Resources are assigned to events. Events can be grouped into processes and operations.
F
feeder line
A production line designed to feed subassemblies to a line producing higher level assemblies.
feeder line synchronization
A concurrent process enabling you to synchronize subassembly flow schedule sequences with the parent assembly line flow schedule.
flexible tolerance fences
Used to represent the flexibility of supplier capacity. Shown as the percent increase or decrease over daily production rate available, from a given supplier, for a set amount of time. Flexible tolerance fences provide temporary increases to capacity to handle increases in orders. The line rate is adjusted by the tolerance fence percentage before scheduling rules are applied. Tolerance fences are set up when creating line definition.
fixed component usage
Component usage quantity that is fixed irrespective of the build quantity of the assembly item.
flow line
The physical location where you manufacture a flow assembly, usually associated with a routing. You can build many different assemblies on the same line at the same time. Also known as assembly line.
Flow Manufacturing
Manufacturing philosophy utilizing production lines and schedules instead of work orders to drive production. Mixed models are grouped into families and produced on lines, balanced, to the TAKT time.
flow routing
A sequence of manufacturing events that you perform to manufacture an assembly. A routing consists of an item, a series of events, processes and/or operations, a operation sequences, operation effective dates, and a flow routing network.
flow schedule
Represents the volume and mix of products to be produced. Scheduling can be done based on customer orders, with an objective of matching the customer orders as closely as possible while establishing an achievable pace and consistent flow of products. Schedules do not produce work orders.
J
just-in-time
A system for producing and delivering the right items, at the right time, in the right amounts, at the right place The key elements are flow, pull, standard work and TAKT time.
I
IPK (In Process Kanban)
Designated as a work in process holding area for work in between operations. If the operation time for one operation is shorter in length than the next operation—the IPK is a buffer area where the item is designated until the next operation is available. The calculation is:(elapsed weighted time - line takt time) * hours/day * time conversion factor divided by elapsed weighted time * line TAKT time
K
kanban
A method of production that uses standard containers or lot sizes with a single card attached to each. It is a pull system, work centers signal with a card that they wish to withdraw parts from feeding operations or suppliers. The Japanese word kanban, loosely translated, means card, billboard, or sign.
kanban allocation percent
Percent of independent demand for the kanban item that is to be supplied from a given pull sequence.
kanban card
The visual replenishment signal. It corresponds to a kanban bin. Replenishable kanban cards are based on pull sequences; non-replenishable cards can be created manually.
kanban chain
A series of kanban pull sequences that model the replenishment network on the shop floor.
kanban location
The designated location where a kanban bin is stored, and where the replenishment is delivered.
kanban size
The number of items in each kanban bin.
L
Lean manufacturing
Refers to the elimination of wastes in a process—these are tasks that do not add value. Lean production aims to eliminate waste in every area of production including customer relations, product design, supplier networks, and production floor management.
line balancing
Organizing work on the production line so that resources can be synchronized to daily demand.
line operations
Regrouping of events on a flow routing to achieve approximate TAKT time. Line operations are line specific and are derived and defined during line balancing.
M
mixed model production
Enables a mix of products to be built on one production line. Mixed models are grouped into families and built on lines balanced to the TAKT time.
mixed model map
Tool used to design balanced lines. The projected volume and mix of demand for a group of products is used to calculate weighted average work content times. These averages are compared to TAKT time to regroup events into balanced operations, and reallocate resources.
N
net planning percent
Percent of product that passes through a process or line operation. It is the sum of the product of the network percentages at each operation along each path.
non-replenishable kanban
Used to replenish a kanban location for one instance. This card is used typically for custom products, onetime customer orders, or sudden spikes in demand.
O
operation time
The total of setup and run time for a specific task. In Flow Manufacturing, operation time includes the machine time, labor time, and elapsed time for events, processes, and line operations on your flow routing.
operation yield
The percent of material that passes through an operation, process or event on a flow line without being scrapped.
operational cycle time
See TAKT time.
operational method sheet (OMS)
Operational method sheets (OMS) are documents that describe the operation to be performed for an assembly. The information in the OMS often includes graphical representation of the process, material needed, and detailed work instructions. You can use attachments in Oracle Flow Manufacturing to attach OMS's to line operations in the flow routing.
P
phantom
An item or component which is never stocked and is used as a part in building the final item.
point of use (POU)
Inventory located at a specific operation on a flow line where it will be used. Material is pulled from these locations using a kanban signal. These locations are supplied from either raw material stores or directly from the supplier.
process
A planned series of actions or operations (such as. mechanical, electrical, chemical, inspection, or test) that advances a material or procedure from one stage of completion to another. In Flow Manufacturing, processes are generic activities on a flow routing that often consist of several events performed in a specific sequence. They are specific to a line, and are often defined during the analysis on a flow line.
process volume
The number of items an operation has added value per day. Calculated process volumes represent the projected number of work units by process/line operation. These numbers are influenced by the demand mix, routing resource requirements, routing networks (alternate paths, rework loop percentages), net planning percentages, and yields.
product family
A group of products with similar characteristics, often used in production planning. Flow product families often have similar product synchronization.
product synchronization
Process of defining events, processes, and operations and assigning them to a flow routing in a specific sequence they are performed.
production lines
Manufacturing work areas where you manufacture families of products.
pull sequence
A body of information that defines the kanban location, source information, and planning parameters required to calculate the kanban size for a given kanban bin. Replenishment chains are created by multiple pull sequences.
R
replenishable kanban
A replenishable kanban card cycles through the system until it is put on temporary hold, or completely removed from the replenishment cycle.
reverse cumulative yield
Product of the yields at each operation, process, or event on a flow line—starting with the last operation, process, or event.
roll flow schedules
A function where you can move the flow schedules you did not complete into the next available day, or use overcompletion quantities for future schedules.
routing network
A process-map of your processes and operations where you specify the primary path, alternate paths, feeder lines and rework loops within your flow line. Defines the flow of work from one line operation to the next.
S
scheduling rule
Basic rules are used in a scheduling system. Scheduling rules specify the amount of calendar time to allow for a move, queue, and load calculation.
T
TAKT
A German word for beat. It is a statement of hours divided by demand. The flow line and every process/line operation is measured against required TAKT:
Line TAKT is the rate the line produces one item to fulfill the demands (Hours per Day / Daily Demand)
Operation TAKT is the rate the operation produces one item to fulfill the operation demands (Hours per Day / Process Volume)
total product cycle time (TPCT)
The total time along the longest path of your flow routing. Calculated by taking the sum of the elapsed times, along the longest primary path on the routing network.