Oracle Project Manufacturing supports companies in the engineer-to-order, make-to-order, Seiban, and aerospace and defense industries. These industries plan, track, procure, and cost based on project, contract, or Seiban numbers.
Oracle Project Manufacturing supports the following key areas:
Contract or sales management and fulfillment, including drop shipments
Advanced supply chain planning
Costing
Procurement
Shop floor execution, including flow manufacturing
Project Inventory tracking including warehouse management
Project Manufacturing quality management
Assemble-to-order and pick-to-order environments
Task auto-assignment workbench
Workflow-based schedule exception messages
Workflow-based project MRP exception messages, with project reschedule-in, reschedule-out, and cancellation messages
Common supply netting for hard pegged material
Workflow-based manufacturing project definition flow
Seiban wizard and Seiban job costing
Project data in EDI purchase order and purchase order change transactions
Workflow-based inventory move orders for project material
Project manufacturing organization parameters
Project Manufacturing Inquiry support for querying information of PSI (project status inquiry including project actuals and commitments), project expenditures, project budgets and budget revisions, WIP job drill down to operations and material, cost group history drill down, and flow schedules
In addition, Oracle Projects provides the following features:
Work breakdown structure definition
Project management system integration
Budgeting and funding
Cost tracking and control
Cash forecasting
Billing
Revenue recognition
Archive and purge
Model/unit effectivity (serial effectivity)
Borrow payback
Invoice cost transfer (for actual costing)
Common project
Inter-org project manufacturing costing
Project return material authorizations
Pick Release by project and task
Integration with Oracle Advanced Supply Chain Planning
Project cash forecasting (integration with Oracle Cash Management)
Multinational projects (currency and tax)
Cost allocations
Graphical T-Accounts
Archive and purge
Intercompany and inter-project billing
The following key features are supported specifically for the Aerospace and Defense industry:
Model or unit effectivity (serial effectivity)
Borrow payback
Hard and soft full pegging across the supply chain
Group netting
Actual costing (moving weighted average method)
Complete integration with Oracle Advanced Planning and Scheduling
Complete integration with Oracle Flow Manufacturing
Overview of Project Contracts, Project Contracts User's Guide
Overview of Cost Management, Oracle Cost Management User's Guide
Overview of Flow Manufacturing, Oracle Flow Manufacturing User's Guide
Overview of Bills of Materials, Oracle Bills of Materials User's Guide
Overview of Configure to Order, Oracle Bills of Materials User's Guide
Overview of On-hand and Availability, Oracle Inventory User's Guide
Serial Number Control, Oracle Inventory User's Guide
Overview of Oracle Quality, Oracle Quality User's Guide
Overview of Budgeting, Oracle General Ledger User Guide
Bills Receivable Overview, Oracle Receivables User Guide
Oracle Project Manufacturing integrates with the Oracle Projects, Oracle Financials, Oracle Human Resources, Oracle Customer Relationship Management, Oracle Business Intelligence System, and Oracle Advanced Supply Chain Management product suites. The following figure depicts the integration points.
Overview of Cost Management, Oracle Cost Management User's Guide
Overview of Flow Manufacturing, Oracle Flow Manufacturing User's Guide
Serial Number Control, Oracle Inventory User's Guide
Overview of Oracle Quality, Oracle Quality User's Guide
Overview of Budgeting, Oracle General Ledger User Guide
Bills Receivable Overview, Oracle Receivables User Guide
Oracle Project Costing, Oracle Projects User's Guide
Oracle Project Billing, Oracle Projects User's Guide
A contract cycle begins with a bid and proposal process by sales and engineering. This process includes review of profit margins and actual status on similar projects, calculation of a high-level project schedule to determine a rough-cut project duration, engineering reviews with optional new product introduction, infinite or constraint-based capacity simulation, procurement analysis for contract specific out-sourcing and requests for supplier quotes. The final result is a bid.
After the customer awards the contract, you define the project work breakdown structure and the budgeting and reporting requirements then submit for approval. The work breakdown structure represents all project activities including tasks, sub-tasks, work packages, activities, and milestones.
Project demand enters into the execution and planning system. The planning system runs a single or multiple plans across the supply chain and optimizes as needed based on constraints. Simulation of alternates provides the information required to determine the optimal scenario. The system analyzes specific project exception messages at the outcome of each planning run. It forwards the planning results to procurement and the shop floor for execution. You can route drop shipped material directly to procurement from order management, bypassing planning.
Shop floor execution uses discrete work orders, flow schedules, or a combination to manufacture (sub)assemblies. Procurement uses either blanket releases or standard purchase orders, based on the project specific supplier quotes, for procured material. The system tracks all project specific material (hard pegged) separately in the system, and permits borrowing or permanent transfers from one project to another. Also, you can track project specific quality data and analyze defects and non-conformances.
During execution, the system collects direct and indirect actual costs by project. You can analyze costs for a specific project or across multiple projects. Based on actual costs, you can perform earned value analysis, progress billing, and revenue recognition. During the execution phase the system collects quality data and analyzes it by project.
After the project is shipped and installed at the customer site, final billing, reconciliation, and close-out execute.
Creating Projects, Oracle Projects User's Guide
Overview of Shipping, Oracle Shipping Execution User's Guide
The following figure illustrates project manufacturing features. It also depicts the dependencies between the various products used to provide a full project manufacturing solution.
In order to define a project work breakdown structure, you can use one of the following methods:
Define the project structure in a third party project management system and transfer the structure into Oracle Projects. Use basic setup data from Oracle Projects, such as project resources, project calendars, and project templates, directly in your third party project management system. Depending on the project management system that you need, use the Oracle Projects Connect or Oracle Projects Activity Management Gateway product.
Define the project structure directly in Oracle Projects.
Define the project structure using the Seiban Number Wizard.
Before you release the project to collect manufacturing costs, define the project-related manufacturing parameters for costing and planning purposes. For example, you need to decide whether to allow netting of materials within a project group across multiple projects or to track manufacturing costs separately by project or for a group of projects. You can also use project attachments to enter project or contract specific documentation.
Seiban Number Wizard, Oracle Project Manufacturing User's Guide
Creating Projects, Oracle Projects User's Guide
Overview of Projects and Tasks, Oracle Projects User's Guide
To track costs against budgets, you can define your budgets in Oracle Projects. You define budgets directly in Oracle Projects or import budgets from external systems. Oracle Projects' main budgeting features are:
Multiple Budget Versions. You can use Oracle Projects to create multiple budget versions that include all of the costs for your project, such as engineering costs, item costs, manufacturing costs, and overheads. Having multiple budget versions enables you to revise your estimate-to-complete many times during a project. Each project can compare the current or baseline budget with earlier versions for analytical reporting.
Unlimited Budget Types. You can create different types of budgets. You can create cost budgets, revenue budgets, forecasted revenue budget, approved cost budget, and more.
Time Phased Budgeting. You can create time periods or use existing calendars in Oracle General Ledger or Oracle Projects to establish multiple budgeting periods.
Budget Extensions. You can use budget extensions to accommodate your company's budgeting needs.
Budget Baselining and Approval. You can baseline a budget and use a workflow-supported approval process for approving your budget.
Budgeting related documents such as spreadsheets can be included as budget attachments.
See Also:
Overview of Project Budgeting and Forecasting, Oracle Project Management User Guide
After your project structure and budgeting have been defined in Oracle Projects, you need to define the Project Manufacturing parameters for your project. These include:
Default WIP Accounting Class
Cost Group, if you are using weighted average costing
Borrow payback variance accounts (optional)
Planning group (optional)
Task auto-assignment parameters (optional)
Expenditure types for IPV, ERV, Freight, Tax, and Miscellaneous; if the parameter Transfer to PA is selected in the Project Manufacturing organization parameters
Project manufacturing costing information:
Link new project expenditure types to new manufacturing cost elements and cost sub-elements (only when using new cost elements).
Link new manufacturing departments to new projects expenditure organizations (only when using new departments).
Optionally, define expenditure types for Invoice Price Variance, Exchange Rate Variance, Freight, Tax, and Miscellaneous Invoice costs.
Optionally, define borrow payback accounts.
Project sales management activities include recording customer quotation documents, project specifications, quotation and sales order information, and fulfillment.
Oracle Project Manufacturing supports:
Project Quotations and Sales Orders. Oracle Order Management allows you to specify quotation and sales orders. A quotation can be copied easily to a sales order. Quotation, and sales order lines can be linked to projects and project tasks.
Project RMA Oracle Order Management allows you to process Project RMAs using the line type category ‘Return'. Examples of the line types available are return for credit without receipt of goods, return for credit with receipt of goods, and return for replacement.
Project Assemble-To-Order (ATO) and Pick-To-Order (PTO). Oracle Project Manufacturing allows you to use the Oracle Configurator with Oracle Order Management with propagation of project and task on the configured model, options, and included items. For ATO, the Final Assembly Schedule process will create a WIP Job with the configuration's project and task.
Project Drop Shipments. You can specify a project and task on a sales order line and automatically create a project purchase requisition using drop shipment functionality. Drop-shipped materials are shipped directly from supplier to customer.
Project Fulfillment. Oracle Order Management and Oracle Shipping Execution support delivery-based shipping with user-definable picking rules for order fulfillment. After manufacturing is complete, finished goods are picked automatically from the project inventory upon pick release. You can also pick all items for a project and task.
Project Order Import. If you use external systems to capture order information you can use Order Import to import external sales orders or quotations, including project and task references.
In order to drive project manufacturing planning, you need to enter demand in the system. The system supports three ways of entering demand:
Forecasts. You can enter a forecast and link a forecast entry to a project and task.
Sales Orders. You can enter a sales order and link a sales order line to a project and task. This can also be accomplished using Order Import functionality.
Master Demand/Master Production Schedule . You can enter a master schedule and link a master schedule entry to a project and task. Forecasts and sales orders can be sources for a master schedule.
After demand is created in the system, you can start your planning cycle. The planning cycle can be executed for a plan that spans one organization or an entire supply chain.
To successfully plan material for project execution, you must be able to separate all sources of supply and demand by project, identify components as shared or project specific, track existing inventories by project, and provide visibility to all supply and demand associated with a project.
Oracle Project Manufacturing provides:
Hard Pegging. You can plan material requirements while respecting hard pegs on all supply orders and generate planned orders with project/task references. Each item can be hard or soft pegged, thereby allowing various pegging methods within a bill of material. Hard pegging is also supported in a supply chain planning scenario.
Soft Pegging. You can plan materials and soft peg them to the demand. Soft pegging is also supported in a supply chain planning scenario.
Group Netting. You can net within a planning group (multiple projects) and you can soft peg items to the projects within the project group.
Common Supply Netting. You can net excess common (non-project) supply to hard pegged demand.
Graphical Pegging to Project. You can use the object navigator to view your pegging information, such as project, task and sales order, graphically.
Planner Workbench. You can use the Planner Workbench to view project exceptions, a project horizontal plan, supply and demand per project, and unit number to simulate new or existing project demand, and to release planned orders by project.
Forecast by Project/Task. You can link a project WBS to a forecast entry and run the forecast demand through the planning system. This enables you to plan long term capacity and procurement for your projects.
Master Schedule by Project/Task. You can load the MDS/MPS from a project forecast with project sales orders or manually link a project WBS to a schedule entry. You can have project and non-project demand in one schedule.
Project Exception Messages. The planning system will generate project related exception messages including: items allocated across projects and tasks, items with excess inventory in a project or task, items with shortage in a project or task, reschedule-in, reschedule-out, and cancellation. You can use the workflow-based exception messages to define collaborative scenarios between internal and external organizations (suppliers and customers).
Single Planning Run for all Projects. You can run a single plan for multiple projects at once, thereby eliminating the need to run planning project by project. Oracle Application's fast memory-based planner allows you to execute planning much faster than traditional planning systems.
Project Planning Simulation. You can enter new supply and demand entries for new project and tasks or change existing supply and demand due dates directly in the Planner Workbench. On-line net-change simulation lets you view the results of your changes in minutes. This allows you to respond easily to scenarios of fluctuating and unexpected demand or to project management system rescheduling results.
Multi-Organization/Multi-Plant and Supply Chain Projects. Using Oracle Project Manufacturing, you can consolidate all costs for the products you manufacture for the same project in multiple plants in Oracle Projects. You can use Oracle Advanced Supply Chain Planning to plan projects across a supply chain with appropriate propagation of project and tasks on internal orders and demand and supply entities.
Constraint-Based Optimization. You can use Oracle Advanced Supply Chain Planning to optimize your project material and capacity plans using a variety of constraints and objective functions.
Borrow Payback Supply and Demand. The planning engine recognizes borrow payback supply and demand.
The planning cycle results in planned orders that are fed into the execution system:
Internal orders driven by intercompany supply
WIP discrete jobs for make items (Project Work In Process)
Flow schedules for make items (Project Work In Process)
Purchase requisitions or blanket releases for buy items (Project Procurement)
The execution system addresses the inventory, shop floor, and procurement activities. Project manufacturing costs are collected during execution.
Oracle Project Manufacturing supports the following features for Project Work In Process:
Project WIP Jobs. You can create WIP Jobs with project/task references. Project Manufacturing supports standard and non-standard WIP Jobs. You can create Standard Project WIP Jobs automatically and release them from the Planner Workbench.
Project Outside Processing . You can use existing outside processing functionality to support Project Outside Processing. The system transfers the project/task on the work order once the outside processed purchase requisition generates.
Project Repair Orders. You can link nonstandard WIP Jobs to a project / task to capture project repair.
Project Flow Schedules. You can use flow schedules in a work orderless production environment. Flow schedules can be created and released from the Planner Workbench or the Line Scheduling Workbench.
Oracle Project Manufacturing supports the following features for Project Procurement:
Project Requisitions. You can create requisitions with project/task references. Project requisitions can be defined for inventory and expense destination types. Project requisitions can be implemented automatically from the Planner Workbench.
Project Purchase Orders. You can create purchase orders with project or task references. Project purchase orders can be defined for inventory and expense destination types.
Project Blanket Releases. You can create purchase blanket releases with project/task references. Project blanket releases can be automatically implemented from the Planner Workbench.
Project RFQs. You can create purchase request for quotations (RFQ) manually or autocreate an RFQ from a requisition. You can request multiple quotes within one vendor RFQ.
Project Supplier Quotes. You can create purchase vendor quotes manually or create a quote from an RFQ.
Project Outside Processing. You can create purchase orders for outside processing directly from Oracle Work In Process.
Overview of Creating Discrete Jobs, Oracle Work in Process User's Guide
Overview of Non-Standard Discrete Jobs, Oracle Work in Process User's Guide
Overview of Outside Processing, Oracle Work in Process User's Guide
Overview of Requisitions, Oracle Purchasing User's Guide
Overview of Purchase Orders, Oracle Purchasing User's Guide
Purchase Order Types, Oracle Purchasing User's Guide
Overview of Sourcing, RFQs and Quotations, Oracle Purchasing User's Guide
Tracking inventory by project and dealing with permanent and temporary transfers from one project to another or from common inventory to project inventory is essential for a project-based environment. Oracle Project Manufacturing supports:
Project Inventory. You can use project locators to segregate inventory by project. Purchase order receipt locators validate automatically for project purchase orders. You can reference existing project locators or dynamically create project locators upon receipt. The issue, back-flush, and completion locators validate automatically for project WIP jobs and associated material. Similar logic applies in processing flow schedules using work orderless completions.
Project Material Transactions. You can use existing material transactions such as Miscellaneous Issue/Receipt, Move Orders, PO Receipt, WIP Issue, WIP Return, and WIP Completion.
Permanent Project to Project Transfers. You can use project transfer transactions to transfer material from one project to another with appropriate transfer of inventory value.
Temporary Project to Project Transfers. You can use borrow payback transactions to borrow material from one project to another, and ensure payback against the original value.
Common-to-Project and Project-to-Common Transfers. You can use project transfer transactions to transfer material from common inventory to project inventory and vice versa, with the appropriate transfer of inventory value.
Project Mass Transfers. You can use the mass transfer wizard to initiate the mass transfer of material from one project to another based on criteria you define, with the appropriate transfer of inventory value. The system generates notifications of approval for the from and to project managers, if the project managers are different.
Consigned Material from Supplier. You can perform implicit and explicit consumption of consigned items to demand/supply documents with project references, with appropriate transfer of inventory value into a project.
Project Warehouse Management. You can enable Warehouse Management and Project Manufacturing in the same organization. You can receive, move, manufacture, pick and ship material owned by a project. You can leverage warehouse resource management, warehouse configuration productivity performance analysis, task scheduling, advanced pick methodologies, and value added services.
After completion of the assembly on the project sales order lines, the goods can be shipped to the customer for installation.
Project Mass Transfer, Oracle Project Manufacturing User's Guide
Defining Stock Locators, Oracle Inventory User's Guide
Overview of Inventory Transactions, Oracle Inventory User's Guide
Defining Pick Methodologies, Oracle Warehouse Management User's Guide
During the execution phase, project-related costs can be collected in four ways:
Import of costs from external systems directly into Oracle Projects' Transaction Import.
Entry of direct labor and expenses directly into Oracle Projects using time and expense entry.
Collection of manufacturing labor, material, and manufacturing overhead in Oracle Cost Management as a result of Work In Process and Inventory transactions.
Import of manufacturing costs from external systems using Oracle Manufacturing Transaction Import.
For expense purchases, the invoice costs flow to a project through Oracle Payables. For inventory purchases, the purchase costs flow to a project through Oracle Cost Management upon receiving into destination. As soon as invoices are matched, approved, and posted to the General Ledger, you can transfer the appropriate invoice charges (IPV, ERV, Freight, Tax, and Miscellaneous) to Oracle Projects, using the Invoice Charge Transfer Request.
For inter-company costs, the system transfers costs at cost group value (determined by FOB point), either collapsed into the material element or with elemental details.
Oracle Project Manufacturing supports project costing with the following features:
Cost Groups. You can create cost groups and link cost groups to projects to identify and separate costs by item and by project. Costs are tracked using perpetual weighted average, FIFO, LIFO, or standard costing methods. Using average costing, you can use one cost group for multiple projects if you want to establish a weighted average cost by item for a group of projects. In standard costing organizations, Cost groups hold the Inventory valuation accounts and links to WIP Accounting classes, but Standard Cost Rates are maintained at the organization level, which means a project cannot maintain a standard rate different from any other project for the same item.
Linking Project Expense Organizations to Manufacturing Departments. You can link project expense organizations to manufacturing departments to allow for departmental cost visibility and analysis for a project.
Common Project. You can define a common project to collect cost for all common material transactions into Oracle Projects. You can use standard tools such as Expenditure Inquiry and Project Status Inquiry to analyze your common project, view commitments and actuals, and compare common and project-specific costs.
Linking Project Cost Elements To Manufacturing Cost Elements You can create user-defined project cost elements (Oracle Projects expenditure types), and manufacturing cost (sub)elements. Project cost elements can be mapped into user definable categories for analysis and reporting. You can specify which project cost elements you will use on an individual project. Oracle Project Manufacturing allows you to link manufacturing cost elements (labor, material, overhead, outside processing), resources, and departments to project cost elements. This allows you to track all costs within a project, whether a given cost's source is purchasing, project direct labor and expenses, shop floor activity, or external systems.
Manufacturing Cost Collector Oracle's Manufacturing Cost Collector allows you to transfer manufacturing costs to Oracle Projects. The engine intelligently derives all required information such as expenditure organization, expenditure date, and project cost element, automatically. All manufacturing costs are transferred to Oracle Project's Transaction Import for project cost distribution. The Cost Collector also calls the Task Auto Assignment Rules to assign tasks to costed transactions when running a project-only manufacturing scenario.
Project Inventory Valuation You can use the full functionality of Weighted Average Actual Costing in a Project Manufacturing environment. Project inventory material costs will be maintained by project on a perpetual weighted average basis. Common inventory material costs will be maintained by item. All costs are maintained per organization on elemental detail.
Oracle Projects supports costing with the following additional features to keep track of project progress, actual-versus-planned budget, control of project purchase commitments, and reporting:
Project Status Inquiry (PSI). Use this feature to research facts about your project. You can go up and down on your project WBS and obtain project summary information, and drill down to detail transaction information. You can also obtain project commitments, revenue, invoices, unbilled costs, backlog and receivable information. The PSI Extension allows you to pull project information from any part of the database. You can export data in on-line queries to your desktop spreadsheet and reporting tools, to meet the requirements of your company.
Project Comparison. Oracle Projects and most project management systems allow you to compare multiple project versions. You can use Oracle Projects to compare baseline and current project budgets.
Project Status Reporting. Both Oracle Projects and most third-party project management systems support a large number of project status reports to analyze your project financial status.
Project Expenditure Types. You can create user defined project cost elements (expenditure types) and group these elements into categories.
The Oracle Business Intelligence System supports management reporting across all projects and all organizations for revenue and cost incurred. Starting from the top level, you can drill down across the organization and classification hierarchies to the project level.
Oracle Projects is the repository for all project costs. These costs can be used for earned value analysis, which is handled in the third-party project management system. The result of the earned value analysis can trigger project billing.
Within the Project Manufacturing solution, there are three ways to accomplish billing:
Drive billing from Oracle Order Management using order types (workflows) that interface to Oracle Receivables.
Drive billing from Oracle Project Billing using billing schedules that interface to Oracle Receivables.
Use a combination of the first two methods. For example, you might drive project billing from Oracle Project Billing and spare-part billing from Oracle Order Management. If you use Oracle Shipping Execution to ship your project-related assemblies, but not to bill for them, use order types (workflows) that do not interface to Oracle Receivables to avoid double billing.
Optionally, you can implement Oracle Quality for managing project quality. Oracle Quality in combination with Oracle Project Manufacturing supports:
Project Quality Collection Elements. You can use project and task as quality collection elements.
Specify Project on Quality Collection Plan. You can specify a project on a quality collection plan.
Project Quality Data Collection. You can collect project and task related quality information using manual entry or Oracle Quality's Data Collection Open Interface.
Project Quality Analysis. You can use project and task as selection criteria for quality analysis.
Figure 1-3 includes Oracle financial products that have not been discussed. If you implement an Oracle Projects functionality called Capital Projects, you will generate asset lines for Oracle Assets. All journals from all subsystems will be posted to Oracle General Ledger. Oracle General Ledger is also the placeholder for the chart of accounts used throughout the entire system.
Oracle Project Manufacturing provides additional special features:
Model/Unit Effectivity (Serial Effectivity). You can define unit effective items and bills of materials, allowing you to implement product structure variations driven by unit number effectivity as opposed to date effectivity. You can engineer, sell, plan, produce, procure, ship, and track against a unit number. Model and unit effectivity can be used in a non-project based environment.
Task Auto Assignment Workbench. You can use the Task Auto Assignment Workbench to define material and resource rules for task allocation. This feature supports scenarios where you intend to run the manufacturing side under project control only. Task Auto Assignment supports a myriad of rules to assign tasks dynamically to project-only manufacturing transactions for more flexible costing scenarios. For example, rather than allocating all costs for a work order to one task, you could implement rules that allow certain resource cost to be allocated to one task, other resource costs to another task, and material costs to be allocated to another.
Project Manufacturing Inquiry. PJM Inquiry, accessed in a separate browser window, allows continuous monitoring of one or more projects. PJM Inquiry shows project related data such as project sales orders, project procurement documents, project discrete jobs with material and operation details, project flow schedules, project cost group with history, project budgeting, project expenditures, and project commitments.
Manufacturing Project Definition. This workflow-based process guides you through the setup steps required to define a project manufacturing project. The process keeps track of completion and can notify you on steps to be done or completed.
Project Schedule Exceptions. This workflow-based process assists you in identifying project schedule inconsistencies. Inconsistencies can be sent to project and task managers using workflow notifications or standard exception reports. The process monitors overdue work orders, procurement documents, and sales orders, as well as out of sync work orders, procurement documents, planning entries, and sales orders.
Seiban Number Wizard. The Seiban Number Wizard guides you in the definition of Seiban number, which is visible in the system as a project number. Seiban numbers can be represented as unique numbers using Project Manufacturing without Oracle Projects. For ETO-type Seiban or lot-type Seiban, you can define a multilevel project structure in Oracle Projects, or a top-level project structure that can be generated through the wizard.