Oracle E-Business Suite

ETO Extension

Solution Summary

In engineered to order (ETO) manufacturing environments, customer orders typically call for modifications to design and/or specifications of product models. While an engineered to order product provides flexibility and value to customers, it also provides many challenges to the business throughout the entire production cycle. Such challenges include: integration of multiple configuration tools and rules, order processing, Work in Process tracking and management, accurate cost analysis, and the management of customer change orders. New Generation’s Engineered to Order Tracking and Management extension provides a tracking solution for any environment with high variability of product and high volume of transactions. By unifying information from order management through the production process in WIP, it enables the business to review and manage critical information for engineered product in a timely and cost effective way. New Generation’s ETO tracking and management extension provides critical workflows and a WIP Job Dispatching and Management console. Together these tools provide visibility into which work orders are related to which projects/sales order line, what is the total cost of the engineered item, when orders are released and what are the cost implications of a customer change to the order.


Solution Profile:

Overview


Controlling an order as it moves from Order Entry to Manufacturing in an engineer to order environment can be a challenge in Oracle Discrete Manufacturing. Companies need visibility to determine when to release the order, where the subassembly components are in the process, how to control and account for changes to the order and how to cancel and cost related jobs when the order line is canceled. Further complicating the process are complex nested BOMs that generate large numbers of work orders related to the assemblies and sub assemblies that comprise the ETO product.

Oracle Discrete Manufacturing does an excellent job when operations are centered around products that are manufactured, assembled and released to inventory. Orders are completed by picking items, newly created or already in inventory, and shipping. Engineered to order manufacturing presents challenges for any ERP system as each order is in effect a new, distinct product with multiple distinct subassemblies specific to the needs of the customer.

Statement of Problem

In an engineer to order environment, when an order is released to manufacturing, visibility to that order is often not sufficient as the emphasis of Discrete manufacturing is on organizing parts and assemblies for orders into efficient discrete batches. Further, the work orders for the lower level subassemblies driven by the Top level ETO item are not linked to a sales order or their parent work order, and challenges arise when attempting to render a 360 degree view of where an ETO is in the production process. Additionally, shop floor planning for the movement of all these parts and assemblies related to a specific order through all work stations in an organized fashion becomes a challenge.

Concerns revolving around work in process management and work in process tracking include:

Test Difficulty in identifying which work orders, other than the top level assemblies, are associated to what sales order demand.
Test Excessive number of transactions in WIP to manage and track the work orders.
Test Difficulty in identifying which work orders are associated to other work orders (which subassemblies are tied to which final assemblies)
Test Excessive number of work orders transaction tax ability of staff to efficiently process.
Test Inability to generate usable standard reports for Shop Floor paperwork without the need to alter the shop floor flow.
Test Uniqueness of each ETO being ordered may cause a proliferation of part numbers.
Test Creating new work orders or updating existing work orders is often required for customer driven change orders. It is difficult to tie them to the current production schedule and parent demand

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Concerns revolving around changes to orders include:

 

Test Changes to the engineered item often requires canceling the order line as identifying and making changes to the associated work orders is difficult.
Test Difficulty in tracking down all work orders associated with a change order.
Test Difficulty in capturing the associated costs related to the change.
Test Overall management of work order changes.

 

 

 

 

 

 

 

Solution

The focus of the solution is to capture and streamline ETO Order demand from Oracle OM and release it directly into WIP regardless of which Configuarator system the demand originated from. By utilizing Oracle’s workflow capabilities and a custom WIP dispatching form , we are able to create discrete jobs in the WIP module for the top level assemblies and any make to order components specified at any level in the BOM. All jobs are linked to their respective sales order line, CAD drawing ID and parent work orders (where applicable). A custom form provides a 360 degree view of all jobs that are associated with a sales order or drawing ID. From this form you are able to manage all work orders and their release statuses. Finally, custom shop floor documents are used to communicate all work instructions to the shop floor. These documents included routing sheets, indented bills of material, as well as a document that grouped different items with like operations so the machine operators could batch disparate jobs across the same resources. These shop floor documents are designed to match legacy format and therefore eliminated the need to alter product flow through the shop floor workstations.

Distinguishing Features

New Generation’s ETO tracking and management extension provides critical workflows and a WIP Job Dispatching and Management console.

Demand Orchestration Solution (DOS)

Solution Summary

Demand orchestration across instances solution is designed to solve the problem of integrating supply chain processes divided across multiple instances oracle erp instances. The solution involves demand management and communication across buyer and seller instances and intercompany accounting across these instances for reconciliation. All demand is routed through the buyer instance as single order and necessary items from seller instance are procured , received and reconciled through BPEL orchestration solution .


Problem Statement

Maintaing a streamlined Supply Chain process is challenging for many major companies as they use segregated platforms across the organization. Companies need processes integrated across platforms that can be executed at the pace of the business and with visibility to sales, purchase orders and invoices. The process is further complicated with the updates to the orders when the item procurement is spanned across multiple systems. Furthermore keeping item, customer and supplier masters in sync across all platforms is also challenging and supply chain problems cannot be solved or streamlined without addressing the customer/supplier/item master issue.

Solution

First aspect of solving this problem is build a master synchronization mechanism across multiple platforms by making one instance as a consolidated instance for masters across instances and secondly to build cross references of these masters linking between all these platforms in middleware and keeping this in sync as the changes flow.

Demand initiated from an instance invokes a process orchestration built in fusion middleware using BPEL upon approval of the concerned purchase order. Supplier instance for the items is identified using the details of the purchase order and the order validation is initiated upon the transaction to the seller instance. Based on the validation results the order is created in seller instance. In case of failures the workflow notifies the business owners based on the rules engine configuration. In certain cases further processing requires a human interaction. This is achieved by the human workflow step of the orchestration.

During the entire process the state of the transactions and corresponding transaction numbers are visible through the business monitoring dashboard built using the sensors built into the transactions.

Distinguishing Features

New Generation Consultants’s Demand Orchestration across Instances Solution (DOS) highlights

Test Fast and streamlined supply chain process with master synchronization across all platforms.
Test Agility to business process and mechanisms to handle exceptions at faster pace
Test Runtime configuration of rules for exceptions
Test Transaction visibility throughout the supply chain process
Test KPI based reporting right through the transactional baseboard for executives
Test Single invoice to customers and improved satisfaction to customer by masking the organization complexity
Test Improved call center process through single master data and transaction numbers
Test Visibility to bottlenecks in the business or process

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

  Contact Us:


   For more information, Please contact:

   info@newgenusa.com

   Phone: 847 483 8560