Manufacturing Shop Floor Labor Collection

Executive Summary
Problem Statement
Highly effective and efficient 3rd Party labor
collection system not compatible with Oracle
Capturing Operational Level Actual Hours against
a Work Order is not Possible.

Results
-Support cost reduction
-Conversion productivity loss avoidance
-Productivity loss avoidance
-P&E upgrade/conversion avoidance

Opportunity Statement
-Eliminate Annual 3rd party support cost
-Avoid P&E expenditure for 3rd party solution
-Retain current real-time labor collection capability
that collects direct labor with the transactions of
standard systems and serves as a basis for
managing productivity

-No increase in collection cost

- Maintained 15 second transaction time
- Maintained auto start calculation
- Avoided additional resource
transactions

CTQs
-No increase in collection cost
-Maximize Oracle standard functionality
Solution
Leverage Oracle Mobile Supply Chain Application
(MSCA) Resource and Move Transaction
day/timestamps as the basis for labor calculations.
Develop the custom logic necessary to calculate
applied time based off of end times. Other than start
of day, start times will not be necessary.
2012 Copyright Genpact. All Rights Reserved.

-Utilized a combination of MSCA 0 qty resource

transactions, normal move transactions an
interface table and custom logic to build a labor
collection system that is more efficient in real-time
collection than anything on the market because it
doesnt require start times for each segment of
work.
-Labor collection design can be leveraged across
Oracle Instance for labor reporting where MSCA
and WIP are implemented. Efficiency metric
requires routings and standards. Limited
utilization available without payroll integration- full
utilization available with it.

Key Features
1.

Reduce labor expense by identifying and trimming nonproductive

paid time

2.

Improve productivity by identifying constraints and bottlenecks

3.

Grow profit margin by understanding and controlling actual labor

expense

2
GE Title or job number
11/18/2014

Benefits
1.

Determine the complete cost of labor by capturing all worked

hours direct and indirect, planned and unplanned, productive
and nonproductive

2.

Capture the type and amount of worked hours using integrated

timekeeping allocated in real time to direct and indirect tasks
and associated output

3.

Identify labor variances and measure shop floor productivity based

on actual hours worked

4.

Gain a single, integrated view of labor, equipment, and WIP for all
activities, from setup to final quality inspection

5.

Capture work orders; pass back complete and accurate labor

allocation data; and find the true reasons for bottlenecks, quality
issues, and inefficiencies

6.

Provide accurate and meaningful product status through all phases

of the production process
3
GE Title or job number
11/18/2014

Labor Collection For Productivity Options

With Oracle Leveraged

Classification: Genpact Internal

Time Clock Process for Employee and Supervisors

Operational
-Simple, intuitive user interface
-Log on to log off transactions 15 seconds
-Immediate successive transactions allowed
-Incorporates work order assembly move transactions
where applicable
-Supports bar code entry of data for user and work
order traveler information
-Lunch is excluded from time calculations
-End of one day to the start of another day is
excluded from time calculations
-Unutilized time during the work day is captured by
operational code
-Gaps in time during the work day captured as
unutilized
-Allows for non-sequential operational reporting
-Labor reporting doesnt impact regular Oracle forms
transactions
Classification: Genpact Internal

Supervisory
-Simple, intuitive supervisory interface
-Supervisory approval of time by employee by day
-Error detection and correction capability up to
work order complete status
-Transactional freeze at work order close status

Process Flow

Classification: Genpact Internal

Utilization Report Sample By Employee

IWB

IWB
Work-Order-Num

Employee
1/6/2014 0:00 Creation Date End
Report
Report-Start-Date
Transaction Code
80002 RES_TRAN
3214764 MOVE_TRAN
3225896 MOVE_TRAN
3214764 MOVE_TRAN

1/7/2014 0:00
Detail
1/6/2014 0:00 Report-End-Date
Operation-Seq-Num

Description
9001 ATTENDANCE ON
20 3810 ASSY
20 3810 Final Assembly
20 3810 ASSY

1/7/2014 0:00 Report Run Time

Transaction-Creation-Date

1/8/2014 11:16

Transaction-Date

Start-Time

End-Time

1/6/2014 7:54
1/6/2014 8:51
1/6/2014 8:57
1/6/2014 9:17

4:30:02 PM
7:54:34 AM
8:51:33 AM
8:57:09 AM

7:54:34 AM
8:51:33 AM
8:57:09 AM
9:17:26 AM

9:30:31 AM 000: 13: 05

3352486 MOVE_TRAN

10 2003 Add Labels/2501 Program

1/6/2014 9:30

1/6/2014 9:30

9:17:26 AM

3358091 MOVE_TRAN
3214764 MOVE_TRAN
3225896 MOVE_TRAN
3225743 RES_TRAN
80002 RES_TRAN
3225743 MOVE_TRAN
3225743 MOVE_TRAN
3225743 MOVE_TRAN
3221833 MOVE_TRAN

10 2003 Add Labels/2501 Program

20 3810 ASSY
20 3810 Final Assembly
20 3810 ASSY
2 BREAK
20 3810 ASSY
20 3810 ASSY
20 3810 ASSY
20 3810 Final Assembly

1/6/2014 9:31
1/6/2014 9:43
1/6/2014 9:47
1/6/2014 10:00
1/6/2014 10:21
1/6/2014 11:15
1/6/2014 11:37
1/6/2014 11:56
1/6/2014 12:17

1/6/2014 9:30
1/6/2014 9:43
1/6/2014 9:47
1/6/2014 10:00
1/6/2014 10:21
1/6/2014 11:15
1/6/2014 11:37
1/6/2014 11:56
1/6/2014 12:17

9:30:31 AM
9:30:51 AM
9:43:38 AM
9:47:52 AM
10:00:19 AM
10:21:46 AM
11:15:02 AM
11:37:23 AM
11:56:26 AM

Export
Capable

Classification: Genpact Internal

Time-Difference
063: 24: 32
000: 56: 59
000: 05: 36
000: 20: 16

1/6/2014 7:54
1/6/2014 8:51
1/6/2014 8:57
1/6/2014 9:17

9:30:51 AM
9:43:38 AM
9:47:52 AM
10:00:19 AM
10:21:46 AM
11:15:02 AM
11:37:23 AM
11:56:26 AM
12:17:16 PM

000: 00: 19
000: 12: 47
000: 04: 14
000: 12: 27
000: 21: 26
000: 53: 15
000: 22: 20
000: 19: 03
000: 20: 50

Drill Through To
Individual Transactions

HH:MM:SS-to-Decimal
63.40888889
0.94972222
0.09333333
0.33805556
0.21805556
0.00555556
0.21305556
0.07055556
0.2075
0.3575
0.88777778
0.3725
0.3175
0.34722222

Impact on Manufacturing Elements

Resource
Cost

Operations &

Routings

Departments

Capture
Actual
Hours
MSCA

Resources

WIP
Resource
Transactions

Classification: Genpact Internal

References
1. GE TRANSPORTATION ICS US
2. GE TRANSPORTATION FAIRCHILD

2012 Copyright Genpact. All Rights Reserved.