OPM Production Management

ORACLE APPLICATIONS

Approval Record

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Table of Contents
1.
2.
3.
4.

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6.

7.

Overview......................................................................................................................5
Managing FPOs...........................................................................................................6
2.1 Create FPOs...........................................................................................................6
2.2 Converting FPOs to Batches..................................................................................8
Batch Creation.............................................................................................................9
Manage Production Process.......................................................................................10
4.1 Batch Release.......................................................................................................11
4.2 Step Release.........................................................................................................12
4.3 EMCM Management...........................................................................................14
4.4 Step Completion..................................................................................................15
4.5 Batch Completion................................................................................................16
4.6 EMRM Management...........................................................................................17
4.7 FG, Recovery and Control sample Qty management..........................................18
4.8 Batch Close..........................................................................................................19
Inquiries.....................................................................................................................20
5.1 Running a Production Schedule Inquiry..............................................................20
5.2 Running a WIP Inquiry........................................................................................21
5.3 Running a Material Variance Inquiry...................................................................22
Reports.......................................................................................................................23
6.1 Running the Batch Pick List Report....................................................................23
6.2 Running the Batch Ticket Report.........................................................................24
6.3 Running the Batch Yield Variance Report...........................................................25
6.4 Running the Production Activity Report.............................................................26
6.5 Running the Material Usage & Substitution Variance Report.............................27
Process Execution Workbench...................................................................................28

1. Overview
The primary function of the OPM Production Management module is to record
information about production batches. With this module, one can schedule production
batches, create firmed planned orders (FPOs), convert FPOs into single or multiple
production Batches.
In addition the PM module is used to allocate ingredients, record actual ingredient usage,
certify and complete production batches and record actual product production quantities
among other production processes. One has to use the PM module in conjunction with the
OPM Material Requirement Planning (MRP) module to plan production schedule.
When OPM MRP is executed, it gives suggestion for the Production of the Finished
Goods which are required either from Forecast or Sales Orders. Firm Planned Orders, are
created depending on these suggestion. These Firm Planned Orders are then converted
into Batches.
PM Module lets you do:

Plan the production schedule with information from process planning applications

Create firm planned orders (Independent of MRP suggestions)

Convert firm planned orders into single or multiple production batches

Schedule production batches

Allocate ingredients for batch production

Record actual ingredient usage

Record actual resource usage

Complete and close production batches

Record actual product production quantities

Analyze variances in actual production quantities used as compared to planned

quantities

2. Managing FPOs
2.1 Create FPOs
Firm Planned Orders are designed for medium and long range production planning.
Inventory planners manage discrepancies between net requirements and actual orders that
cover them. Unplanned events can change gross requirements. Planners cannot change
the actual quantities of these gross requirements directly; however they can change the
timing and quantities of material on orders. The firm planned order enables them to do
this.
You create firm planned orders:
From the MRP Action Messages Inquiry
On the Create Batch/Firm Planned Order window.
Navigation Path: OPM Production > Create Documents or Firm Planned Orders
Steps:
1. Enter the appropriate Document Type to indicate entry of a Batch or creation of a
Firm Planned Order. The default Document Type is Batch.
2. A document number is assigned automatically and displays in this field after the
batch is saved.
3. Enter the WIP Warehouse as the work in process warehouse for the batch or firm
planned order. If no entry is made here, then the application selects the default
WIP Warehouse from the plant warehouse rules (defined in MPS application).
4. Click one of the following regions to enter the batch or firm planned order:
Recipe to enter by specifying a recipe version with its default output
quantity.
Or Product Output to enter by specifying the quantity of a product
Or Total Output to enter by specifying a recipe version and a required
output quantity.
Or Total Input to enter by specifying a recipe version and defined input
quantity.
Note: Firm Planned Orders will not be created in the Production Process. These will be
made in the Planning Process.

Fig. 2.1: Create FPOs

2.2 Converting FPOs to Batches

The Convert Firm Planned Order to Batch window enables the user to create one or
more batches based on the firm planned order.
Navigation Path: OPM Production> FPOs
Steps:
1. Select Convert to Batch from the Actions menu of the Firm Planned Order
window.
2. Select quantity per batch, select number of batches to be made from this FPO.
Any unassigned quantity to batches can be seen on this window. When query is
done on this FPO after creating Batches, one can see pending FPO quantity as this
unassigned quantity.
3. Planned start date and end date will be calculated automatically from the routing
details (if not defined then lead time). If product already has a routing defined
then there is no need to specify any lead time
4. Define offset type and offset time to specify time needed to start the next batch.

Fig. 2.2: Covert FPO to Batch

3. Batch Creation
Batches are created from From FPOs- Check earlier section on Convert FPOs to Batches
From the MRP Action Messages Inquiry- When MRP action messages are
approved, one can select document type as batches to directly create Batches.
On the Create Batch/Firm Planned Order window- The process of making Batches
in production responsibility is similar to that of making FPO. Check earlier
section on creating FPOs; instead of selecting document type as FPO choose
Batches.
Navigation Path: OPM Production > Create Documents

Fig. 3: Create Batches

4. Manage Production Process

The creation of a batch and its movement through production occurs with the assignment
of four statuses:
Pending
Work in Process
Completed
Closed
Batch steps are also assigned these statuses during the production process. Batch status
and batch step status are controlled manually or automatically. If a batch is cancelled,
then it is assigned the status Cancelled.
Batch Processing Steps:
1. Release the Batch, Status changes from pending to WIP.
2. Release the steps, in this stage material is consumed (if consumption parameter
for ingredient is set as Stepwise consumption).
3. During step processing on the step quantity window, mention actual step output in
the actual field.
4. For EMCM (excess material consumption) allocate actual quantity used on the
line allocation window. This step should be performed at the WIP stage.
5. Complete the last step; system will prompt the user to allocate FG.
6. Allocate the FG quantity (full planned quantity to be allocated at this stage). Lot
number in this case will be the lot number used on the shop floor.
7. Complete the batch.
8. For EMRM (excess material return) allocate actual quantity used on the line
allocation window.
9. At this stage, go to line allocation window for FG. Allocate actual quantity
produced. Allocate recovery item quantity to same lot but different location
(recovery location). Same way allocate control sample quantity to same lot
number but control sample location.
10. Close the batch.

4.1 Batch Release

Releasing a batch indicates that the batch is started. Batches that contain automatic
consumption ingredients consume these ingredients upon release as long as these
ingredients are allocated. You release a batch by selecting Release from the Actions menu
on appropriate windows.
Navigation Path: OPM Production> Batches
Steps:
1.
2.
3.
4.

Navigate to the Batches window.

Query the batch Document you to release.
Choose Release from the Actions menu. The Release Batch dialog box displays.
Enter the Actual Start Date for the batch. Click OK.

Fig.4.1: Batch Release

4.2 Step Release

Navigation Path: OPM Production > Batches > Steps
Steps:
1. On the Batch window, click on Steps.
2. Select the step to be released, from Action menu select release step.

Fig.4.2 (a): Step Release

3. On the step material detail window, user will mention the actual output in the
Actual field. This information is captured to calculate step-wise yield.

Fig.4.2 (b): Actual output after each step

4.3 EMCM Management

At Step release stage, allocate actual quantity used for EMCM.
Navigation Path: OPM Production > Batches > Steps
Steps:
1. Select Material details tab on batch window.
2. Select the item for EMCM. Click on Line allocation tab.
3. On line allocation window, put actual quantity used in the allocated quantity.
Click OK.

Fig.4.3: EMCM

4.4 Step Completion

Navigation Path: OPM Production > Batches > Steps
Steps:
1. Select the final step.
2. During final step completion, system will prompt the user to allocate FG. Allocate
total planned quantity (system will not accept lesser than planned quantity at this
stage).
3. On clicking OK on this prompt, line allocation window for FG will pop up. Enter
the required details (like Location-FG, Lot same as used on the shop floor).
Click OK.

Fig.4.4: Step Completion

4.5 Batch Completion

Completing a batch indicates that the batch is finished and has yielded all of its product
materials. Prior to batch completion, transactions that are associated with the product and
byproduct lines that are set for automatic yield have a Pending status. When user
completes the batch, all pending transactions are completed and inventory levels are
updated. When user attempts to complete a batch, any outstanding issues related to batch
completion are analyzed by a set of business rules. Appropriate error messages display to
manage these issues prior to closing the batch.
Navigation Path: OPM Production > Batches > Steps
Steps:
1. On the batch window, Choose Complete from the Actions menu. The Complete a
Batch dialog box displays.
2. Enter the Actual Completion Date as the date the batch was completed.

Fig.4.5: Batch Completion

4.6 EMRM Management

After completing Batch, update information for EMRM.
Navigation Path: OPM Production > Batches > Steps
Steps:
4. Select Material details tab on batch window.
5. Select the item for EMRM. Click on Line allocation tab.
6. On line allocation window, put actual quantity used in the allocated quantity.
Click OK.

Fig.4.6: EMRM

4.7 FG, Recovery and Control sample Qty management

After completing Batch, actual FG output is allocated. During this stage details of
Recovery item and Control sample quantity are captured.
Navigation Path: OPM Production > Batches > Material Details
Steps:
1. On the batch Material details window select FG and click on the Line allocation.
2. Allocate actual FG output to FG location and a lot number (that is used on the
shop floor)
3. Allocate recovered quantity to Recovery location and same lot number as FG.
4. Allocate control sample quantity to Sample location and same lot number as FG.

Fig.4.7: FG, Recovery and Control sample Qty management

4.8 Batch Close

The Close Batch dialog box lets the user close a batch. Batch status must be Completed
to close a batch. Batches cannot be closed if any step in the batch is Pending or Work in
Process. All batch steps must have a status of Completed or Closed to close a batch.
Closing a batch prevents any further editing of the batch. This must be done after user is
confident that all of the batch information is recorded correctly.
Navigation Path: OPM Production > Batches
Steps:
On the batch window Choose Close from the Action menu. The Close Batch
dialog box displays.
2. Enter the Batch close date. Click OK.
1.

Fig.4.8: Batch Close

5. Inquiries
5.1 Running a Production Schedule Inquiry
The Production Schedule Selection Criteria dialog box lets you limit the list of production
schedules displayed. When you accept the selected criteria entered, the Production
Schedule window lists the scheduled batches and firm planned orders that meet those
criteria.
Navigation Path: OPM Production > Inquiries > Production Schedule
Steps:
1. Navigate to the Production Schedule Selection Criteria dialog box. Enter a
code for the Plant that has scheduled the batches or firm planned orders.
2. Enter parameters to specify the Type and Status of Production Schedule to
display:

Fig.5.1: Production Schedule Inquiries

5.2 Running a WIP Inquiry

The Work in Process Inquiry Selection Criteria dialog box lets you generate a Work in
Process Inquiry to view detailed information about batches that are in process. Narrow
the inquiry by using selection criteria that limit the data displayed
The Work in Process inquiry provides important information about batches that are in
process including their scheduled completion; number of steps completed, and total steps
that remain active. The inquiry is a good indicator of percent batch completion.
Navigation Path: OPM Production > Inquiries > WIP
Steps:
1. Navigate to the WIP Selection Criteria dialog box.
2. Enter parameters to specify the Type and Status of Production Schedule to
display.

Fig.5.2: WIP Inquiry

5.3 Running a Material Variance Inquiry

The Material Variance Inquiry window lets you display the variances observed between
actual and planned batch quantities. The material variance is expressed as a percent.
Optimize and troubleshoot the production run by monitoring the actual amounts of
material produced in batches. Variances also help monitor production costs by signaling a
process that is outside an expected production tolerance.
Navigation Path: OPM Production > Inquiries > Material Variance
Steps:
1. Navigate to the Material Variance Selection Criteria dialog box.
2. Enter parameters. Click OK.
3. Click on each line to drill down the details.

Fig.5.3: Material Variance Inquiry

6. Reports
6.1 Running the Batch Pick List Report
The Batch Pick List report identifies the material that must be picked for production
batches. If you allocate ingredients before releasing batches, then the Batch Pick List
report identifies the lots that must be picked and the warehouse locations where the
ingredients must be picked. Use the Batch Pick List as a guide to picking material before
actual allocation.
Navigation Path: OPM Production > Reports > Batch Pick List Report
Steps:
1. Navigate to submit Report window. Select Batch Pick List Report.
2. Enter parameters. Click OK.

Fig.6.1: Batch Pick List Report

6.2 Running the Batch Ticket Report

The Batch Ticket report prints one or more batch tickets. Batch tickets identify the batch
document number and include information about the recipe used to produce the batch,
planned start date, planned completion date, required completion date, and specific items
and item quantities to be used in manufacturing the batch.
Navigation Path: OPM Production > Reports > Batch Ticket Report
Steps:
1. Navigate to submit Report window. Select Batch Ticket Report.
2. Enter parameters. Click OK.

Fig.6.2: Batch Ticket Report

6.3 Running the Batch Yield Variance Report

The Batch Yield Variance report displays the actual and calculated batch yield. The report
helps you evaluate differences between specified recipe yield and actual batch yield.
Variances are calculated based on the accounting cost for each item used in the batch. You
are able to specify a date range, an item range, and a range of batches, the sort order, and
where to print the report.
Navigation Path: OPM Production > Reports > Batch Yield variance Report
Steps:
1. Navigate to submit Report window. Select Batch Yield variance Report.
2. Enter parameters. Click OK.

Fig.6.3: Batch Yield Variance Report

6.4 Running the Production Activity Report

The Production Activity report shows scheduled batch and firm planned order production
activities. Unreleased batches that have a status of Pending are reported. Specify the
range of batches or firm planned orders, the date range, the sort order, and where to print
the report.
Navigation Path: OPM Production > Reports > Production Activity Report
Steps:
1. Navigate to submit Report window. Select Production Activity Report.
2. Enter parameters. Click OK.

Fig.6.4: Production Activity Report

6.5 Running the Material Usage & Substitution Variance

Report
The Material Usage and Substitution Variance report displays the actual and calculated
batch yield. The report identifies batches with unusual usage costs and provides a cost
comparison and variance of actual costs against the standard usage that must be incurred
as setup for each formula. Variances are calculated based on the accounting cost for each
item used in the batch. You are able to specify a date range, an item range, and a range of
batches, the sort order, and where to print the report.
Navigation Path: OPM Production > Reports > Material Usage & Substitution Variance
Report
Steps:
1. Navigate to submit Report window. Select Material Usage & Substitution
Variance Report
2. Enter parameters. Click OK.

Fig.6.5: Material Usage and Substitution Variance

7. Process Execution Workbench

Through the Process Execution Workbench, one can view summary information about
batches and firm planned orders by batch, firm planned order, plant, product, and status.
The Process Execution Workbench provides access to information about batches and firm
planned orders through a navigator. There are two tabs located on the navigator - Batches
and Firm Planned Orders. Click either the Batches or Firm Planned Orders tab to access
the summary information that you are interested in. The batch and firm planned order
summary information windows provide access to batch and firm planned order
maintenance windows so that you can review or edit the data.
Navigation Path: OPM Production > Process Execution Workbench
Steps:
1. Open Process Execution workbench, Select sorting parameters. View
Information on the workbench.

Fig.7: Process Execution Workbench