Oracle Process Manufacturing

Implementing Oracle Process Manufacturing

Craig Marmon Deloitte-Touche

11/24/2013

Oracle Process Manufacturing

First of all, What is OPM (i.e. the product formerly known as GEMMS)?

On July 20, Oracle announced the GEMMS product suite will now be referred to as Oracle Process Manufacturing (OPM). OPM is designed exclusively for process manufacturers
Consumer Packaged Goods
Food, Beverage, Health and Beauty, Household Products

Industrial Products
Chemical, Pharmaceutical, Petroleum, Metals, Mining, Paper and Glass

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Oracle Process Manufacturing

OPM coverage is similar to the Oracle Discrete Manufacturing product suite

Discrete Equivalent
Inventory Purchasing Order Entry Bill Of Materials Work In Process Cost Quality

OPM Modules

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Inventory Purchasing Order Fulfillment Formula Production Process Operations Control Costing Quality Physical Inventory Laboratory Material Requirements Planning Master Production Scheduling Capacity Requirements Planning EC Intrastat

Material Requirements Planning Master Production Scheduling Capacity

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Oracle Process Manufacturing

OPM is currently written in the JAM toolset from JYACC.

The current version of OPM is 4.10.06. It is integrated with Oracle 10.7 It is available in GUI only as a SmartClient. The term SmartClient is an oxymoron. It is highly suggested to use Citrix WinFrame as the client interface. Version 11.0 due in December will be written in Developer 2000 and be integrated with Oracle 11.0 NCA
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OPM Release 4.1 Review

First Delivery - September 1997

Year 2000 Compliance Integration to Oracle Financials
10.7 SC 11.0 in November, 1998 Multi-company support

Advanced Order Processing Inventory and Manufacturing Enhancements

Oracle Process Manufacturing

OPM Release 4.1 - Patches Through 06

All ports released Intrastat support Upgrade i2 integration to 2.9 release

Oracle OPM Rhythm Capacity Planner Oracle Rhythm Factory Planner

SOP improvements
Usability Team

Multi-user batch usage Oracle Financials 11 scheduled for Q4

Oracle Process Manufacturing

OPM Release 4.1 - Decision Support

Discoverer Reports 3.0 Oracle Express - OLAP

Oracle Process Manufacturing

The approach for design and deployment is not unlike other ERP applications

FastTrack4 Oracle
Testing and Delivery

As-Is and To-Be phases can range from 6 weeks to 6 months depending on the amount of change the client requires (i.e. systems replacement versus Reengineering). Most often GEMMS can be implemented in 6 to 10 months start to finish.
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Oracle Process Manufacturing

The first implementation step is to establish a test and development environment

The testing environment is intended as a sandbox for the project team to play The development environment serves as a test bed for new patches and upgrades
Oracle typically releases GEMMS patches every quarter and a major release each year

A training environment may be necessary as regularly scheduled classes are too few and far between
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Oracle Process Manufacturing

Confirming business requirements through testing is extremely important

Moving from To-Be to Will-Be requires confirmation that the processes can be performed in the system as designed. Using process flows as the basis for test scripts is the best method for insuring a comprehensive test. Documenting gaps and locking down the design now will save you from scrambling at go-live
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Oracle Process Manufacturing

When To-be processes are confirmed, its time to start configuring the system

GL is setup first, then GEMMS can proceed. There are only a few data dependencies from Financials
Customers entered prior to Pricing Vendors entered prior to Contracts

The Item Master may be modified if no transactions have yet to occur. Make sure it is correct before on-hand balances are created.
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Oracle Process Manufacturing

You should understand the integration between OPM and ORAFIN

There are four types of Integration between OPM and Financials

Master File Synchronization Functional Drill Down On Line

Nearly one-third of the integration points were upgraded in OPM release 4.1 integrated with Financials 10.7

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Master Files are synched through triggers and a data synchronization utility
Integration
AP FOB Codes AP Terms Codes SalesReps Currency Codes Exchange Rate Types Exchange Rates Customers Customer Association Vendors Vendor Association Shipper Association Warehouse Buyers Shipper Codes Freight Bill Method Items UOM UOM Types

Method Used
C, PL/SQL C, PL/SQL C, PL/SQL C, PL/SQL C, PL/SQL C, PL/SQL C, PL/SQL C, PL/SQL C, PL/SQL View PL/SQL Trigger PL/SQL Trigger PL/SQL Trigger View PL/SQL Trigger PL/SQL Trigger PL/SQL Trigger PL/SQL Trigger
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Oracle Process Manufacturing

Functional Integration is achieved through various OPM utilities

Integration
AP Update GL Update AR Update Invoice Price Credit/Debit Memo Expense Allocation

Method Used
JPL, PL/SQL JPL, PL/SQL C, PL/SQL C, PL/SQL C, PL/SQL C, PL/SQL

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Oracle Process Manufacturing

Drill Downs have been a great selling point of OPM for years.
Integration
AP Payment History AR Invoice History OF GL Drill Down OF AR Drill Down

Method Used
JPL, PL/SQL JPL, PL/SQL Oracle Forms, View Oracle Forms, View

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Oracle Process Manufacturing

On Line Integration allows easy access to information

Integration
Account & Accounting Unit Validation/Lookup Credit Check Chart of Account Fiscal Year & Period Validation/Lookup Fiscal Policy Setup Single Logon

Method Used
JPL, PL/SQL JPL, PL/SQL JPL, PL/SQL JPL, PL/SQL JPL, PL/SQL JPL, Oracle Forms

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Oracle Process Manufacturing

OPM has no open interfaces for auto-data conversion.

Programs have been written in the field to import item master, formula master, pricing and various other tables. Six APIs exist in Process Operations Control to link DCS and PLC devices The GEMMS Technical Reference Manual is your best friend for these activities.

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After the production system is fully loaded, a stress test should be performed

All major business processes should be tested

Purchase to Pay Order to Cash Make to Demand Financial Close and Reporting

Each module should be unit tested The entire system should be tested to simulate concurrent usage All background processes should be tested MRP, Cost Update, Data Synch, Test Subledger
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Oracle Process Manufacturing

Its time to begin the system cutover

End-User Training is best conducted by the client project team member with superuser assistance. Make sure the trainers have taken a course on How Adults Learn. I have had success with Big Bang and the staged implementation approach One of the biggest tasks is the dynamic data conversion for items/lots/locations
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Oracle Process Manufacturing

Heres where OPM is headed in the next year

Release 11.0 Overview

Available First Half of 1999 Integrated to Oracle Financials R11.0 Unified Administration, Oracle Applications Look and Feel Integrated to Oracle Purchasing R11.0 New version of Regulatory Management New Discoverer 3.0 based Cost Analysis tool

Oracle Process Manufacturing

Release 11.0 Technical Summary

Using Developer 2000 tool set Full AOL compliance Discoverer 3.1 Oracle 8 Database support Oracle Web Forms + NCA = WAN Performance

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11.0 Look and Feel Enhancements

Integrated menu displays

Mixed OPM and Financial menus Single source for transactions

Improved data search capabilities

Data query capabilities, view next / previous record

Flex fields replacing user class fields

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Migration Approach

JAM Version
JAM Forms/ Reports
JAM JPL (4GL)

Developer 2000 / AOL

Forms 4.5 Reports 2

PL/SQL

C APIs

Oracle Process Manufacturing Enterprise Data Model

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New Purchasing Features, 11.0

Requisitions
User entered purchase requisitions Expense or Inventory items Workflow based approval

RFQs & Quotations MRO Purchasing Integration with MRP Pay on Receipt

Oracle Process Manufacturing

New Purchasing Features, 11.0

Planned EDI Transactions with the Oracle EDI Gateway

X.12 and EDIFACT
850/ORDERS 860/ORDCHG 832/PRICAT 843/QUOTES 856/DESADV 857 824/APERAK outbound P.O. outbound P.O. change inbound price catalog inbound quotes inbound ship notice inbound ship/billing notice outbound application advice

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New Purchasing Features, 11.0

Oracle Self-Service Web Applications

Web Employees (for requisitioning)
Create/view reqs with a browser

Web Suppliers
Supplier access through a browser View invoices, payments, P.O.s, past due receipts, etc.

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Summary of Oracle Process Manufacturing

Strategy: focus on process industries Release 4.1 Began shipping September 97 Continue to improve quality, customer satisfaction Release 11.0 Convert to Developer/2000 Integrate Oracle Purchasing

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