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Oracle R12 Applications

Bills of Material

TCS Internal
Topics
Glossary (Related Business Terminology)

General Introduction to Bill of Material

Integration with other Modules

Setups

Run Through of End to End Business Processes

Standard Reports & Online Inquires

BOM Tables , APIs/Interfaces

Sample Process Analysis Questions

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Glossary (Related Business Terminology)

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Glossary (Related Business Terminology)
Assembly
Product which is manufactured in the Plant
Need not be Finished goods.
The intermediate product can also be an assembly (it could rather be called as Sub-Assembly).

Component
Materials used for manufacturing the assembly
Components could be raw materials, consumables, by-products etc..

Resource
Require to perform an operation to complete the manufacturing process
Could be machine, employee, space, tools and Outside services.
Resources are assigned to departments and they are in turn assigned to an Operation.

Department
An area with in organization
Consists of one or more people, machines, or suppliers,
Where you want to collect cost and apply overhead while you complete you Operation or an assembly.

Work day Calendar


Defines the valid working days of a manufacturing organization
Contains the repeating pattern of On-days and Off-Days.
All working days need to be defined, as On-Days and all Non-working days
(Holidays) need to be defined as Off-Days.

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Glossary (Related Business Terminology)
Model BOM
BOM includes Options and Option class for the customer to choose his configuration.
Also specifies mandatory items and included items that are required for each configuration for the model.
Models cannot be ordered or built instead the configurations arrived using the model are ordered or built.
The types of model BOM include PTO (Pick to Order) and ATO (Assemble to Order).

Option Class BOM


An Item that helps to group optional components on a BOM.
Becomes a level in your Model BOM.
A mandatory item under an Option class BOM applies for all of its options.
Option class BOM can be either a ATO or a PTO.

Standard BOM
Most common type of BOM used in any discrete manufacturing process,
Lists all the mandatory components required for manufacturing the product

Planning BOM
structure that includes a percentage distribution of its components.
Oracle MS/MRP uses the Planning BOM to plan its components based on the percentage distribution.

Lead Time
Time required to complete a process (could be either a manufacturing process or a procurement process).
Various types of lead-time include, Pre-Processing Lead time, Processing Lead time, Post Processing Lead time,
Fixed Lead time, Variable Lead time, Total Lead time, Cumulative Manufacturing Lead time and Cumulative
Total Lead time.

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General Introduction to Bill of Material

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Module Overview

Bills
By what (components) ?

By how much (component quantity) ?


From where (component replenishment
info) ?
Routings
In what way (operations) ?
Who (resources) ?
How long (manufacturing lead time) ?

Maintains workday calendars


Maintains production bills
Maintains configurable bills with options
Maintains departments, resources
Maintains production routings
Rolls up manufacturing lead times

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Workday Calendar

Workday
Calendar MPS/MRP

WIP

Inventory BOM CRP

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Type of Bills

Computer
Planning Bill
Model
Item
Desktop (80%) Laptop (20%)

Model Bill
256MB RAM Monitor Option
Class Bill
Option
Class Item
16 17
Standard Bill

Picture Tube Cabinet Option

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Resource

Warehouse Available
Space workdays
Available
hours Shift A
Workday Calendar

Shop Floor
Worker
Shift
times

Machine
department

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Routings

New product New product


design BOM

Routing

Engineering

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Indented Bill

A C
Qty = 1 Qty = 2
B Unit Cost = D Unit Cost =
$7 $5
Qty = 3
C Qty = 2 E Unit Cost = $4

Single Level Bills

A Unit Cost = $51


Final Level
Rolled up Cost

Qty = 2 Qty = 1
C Unit Cost = $22 B Unit Cost = $7

1st Level
Rolled up Cost
D E
Qty = 2
Qty = 3
Unit Cost = Indented Bill
Unit Cost = $4
$5

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General Introduction- Oracle Bill of Materials

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Alternate Bill & Alternate Routing

Primary Way of manufacturing CRANK SHAFT

CRANK SHAFT

BILLET DIE SAND

Operations:
10. Heating , 20. Hammering , 30. Forging , 40. Twisting , 50. Heat
Treatment

Alternate Way of manufacturing CRANK SHAFT

CRANK SHAFT

MOLTEN METAL CHEMICAL MOULD

Operations:
10. Treatment , 20. Pouring , 30. Fettling , 40. Grinding , 50. Shot
Alternate Bill: CASTING Blasting , 60. Heat Treatment
Alternate Routing:
CASTING

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General Introduction- Oracle Bill of Materials
Oracle Bill Of Materials covers these major Functions as a part of
Discrete Manufacturing:

Creating and Maintaining Routings

Creating and Maintaining BOM

Defining and Maintaining Lead Times

Manufacturing Scheduling

Oracle E-Records

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Integration with other Modules

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Integration with Other Modules
Model and Configurations Manufacturing BOM

Oracle Cost
OrderManagemen Work in
Oracle WIP
Management
t Process

Bill of
Engineering
Materials
ECO (Engg Change Orders)

Oracle
Inventory
Inventory
Items

MRP Purchasing Costing


Planning BOM Cost Rollups
Outside Processing

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Setups

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BOM Parameters

Bill Levels : Max bill level to explode, limit is 60


Inactive Status: De-activate Configurations program uses this item status for the configured items
Numbering Segment: The numbering segment defined in the OE Validation Org will be used for the
configured items.
Numbering Method: This is used for assigning the unique number for the configured items. There are
various logics used for numbering method. Click on Icon to know more about it.
Create Lower Level Supply: This setup decides the supply creation of lower level Configurations or ATO
Items. Selecting NO will only create supply for the Top level configuration items.
Config BOM Creation Allowed: Enable this in all the organizations where you manufacture or purchase your
configurations.
Use Phantom Routings: If checked will include phantom routing components, resources and Overheads in
the top level assembly. Else only the components are included.
Inherit Phantom Op Seq: Enabling this will inherit op. sequence of their parent assemblies. Else they
maintain their own sequences.
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Define and Build Work Day Calendar
(Required)

(N) Bom>Setup>Calendar (B) >Workday Pattern


Valid working days for a manufacturing organization
Can define one or more workday calendars and assign them to any number of
organizations
any number of organizations can share a calendar.
Can specify the start and end dates, and the weekend schedule for each calendar.
Quarterly Type can be:
4/4/5 Week Pattern: Two four-week periods followed by one five-week period.
5/4/4 Week Pattern: One five-week period followed by two four-week periods.
Calendar Months: Twelve periods per year based on calendar months.
13 Periods: Thirteen four-week periods per year.
Workday Pattern sets Workdays On or Off. October 26, 2017 21
Define and Build Work Day Calendar
(Required)

(B) Times
(N)
Bom>Setup>Calendar>Shifts
Define the shifts as per the business requirements.
There can be multiple shift and each shift can have a start and stop time.

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Define and Build Work Day Calendar
(Required)

(N)
BOM>Setup>Calendar>Dates

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Define Exception Template (Optional)

(N): BOM>Setup>Calendar> (M) Tools>Exception Template


Exception templates define and group deviations to your workday calendar, such as holidays,
downtime, or scheduled maintenance. When defining a workday calendar, specify which
days (or shifts) are on and off. The workday calendar, in combination with the exceptions
to it, determine the work pattern for each organization. There are three ways to apply the
exceptions to the workday calendar:
Selecting individual exception days
Loading them from an exception template, another calendar, and another calendar shift
Copying a set of exceptions from another calendar

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Define Exception Template (Optional)

(N): BOM>Setup>Calendar> (M) Tools> Build

Every time when a calendar is defined or modified, make sure it is Build to bring the changes
in to effect.

! System will throw a note on this

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Define Resources (Optional)

(N): BOM> Routing>Resource

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Define Resources (Optional)

(N): BOM> Routing>Resource (B) Overheads

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Define Resources (Optional)

(N): BOM> Routing>Resource (B) Rates

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Define Departments (Optional)

(N): BOM> Routing> Departments

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Define Departments (Optional)

(N): BOM> Routing> Departments

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Define Profile Options (Required)

(N) Sys Admin>Profiles>Personal


Profiles
>Query by BOM%

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Run Through of End to End Business
Processes

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Define Routings

(N) Navigation: BOM>Routings>Routings


Primary Routing: List of operations most frequently performed to build a product.
Alternate Routing: A different manufacturing process used to produce the same product.
Unlike a new primary routing, specify the item and alternate name to define an alternate
routing.
A primary routing needed before defining an alternate
Any number of alternate routings for an item.
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Define Routings

(N) Navigation: BOM>Routings>Routings

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Define Routings

The Date from which this


routing operation is in
effect.

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Define Routings

Define which operations in a routing record move transactions by defining how resources are consumed
at that operation.
The Count Point and Autocharge check boxes work together.
The Count Point and Autocharge check boxes can be set to either on or off.
However, you cannot set Count Point on and Autocharge off.
When you move assemblies from an operation with Count Point on / Autocharge on operation to another
count point operation set the same way, Work in Process automatically completes all Count Point off /
Autocharge on count point operations between them.
To transact a Count Point off / Autocharge off count point operation, you must explicitly move assemblies
into and out of that operation. Moving assemblies past a Count Point off / Autocharge off count point
operation acts as though the operation did not exist in the routing.
This is particularly useful for rework or debug operations that are performed on a portion of the
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assemblies you process.
Define Routings

Define your Operation


Yield. 100% yield is
represented as 1

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Define Routings

BOM changes done through Engineering Change Orders using Engineering Modules can
be viewed here.

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Define Routings

(N) Navigation: BOM>Routings>Routings>Tools


Some of the additional functions which can be accessed from BOM Screen include:
Rollup Cost, Compute Lead Time, Rollup Lead time, Std Operations, Departments, BOM,
Indented BOM etc

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Define Routings
(N) Navigation: BOM>Routings>Routings Details

Define your completion sub inventory and


locator. This will default in the assembly
completion transactions for the
Completion sub inventory.

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Define Routings
(N) Navigation: BOM>Routings>Operation Resources

You can associate multiple resources with an operation on a routing. For each resource, you can
determine if you want to include that resource in scheduling and lead time calculations. You can also
collect costs for a resource on a routing if you specified the resource as a costed resource.
Define your operation timings in the Usage Rate or Amount based on the basis. A basis of Item indicates
when your charges fluctuate with quantity change. Lot Indicates resource usage quantity is the amount
required per job (Setup Charges).
Set your scheduling options as either Yes or Prior or Next or No. Based on this, the operation will be
either scheduled or scheduled prior to this operation or scheduled next to this operation.
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Define Routings
(N) Navigation: BOM>Routings>Standard Operations

Acts as a template for use in defining future routing operations.


On assigning operation code of standard operation in a routing, Operation information gets copied
You can then modify the operation information in your new operation.

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Define BOM Click here to
(N) Navigation: BOM>BOM know more

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Define BOM
Click here to
BOM Field go back

References
Operation Sequence: Assign your routing operation sequence on this Op.seq to assign your item to
the specific operation. This is used for Backflush transactions.
Planning Percentage: This is where you define your planning percentage for your planning bill.
MRP uses this planning percentage for demand generation.
Yield: The yield is the percentage of the component that survives the manufacturing process. A
yield factor of 0.9 means that only 90% of the usage qty of the component on a bill actually survives
to be incorporated into the finished assembly.
Supply Sub inventory and Locator: Work in Process pulls components from the supply sub
inventory and the locator within the sub inventory during back flushing. Assign a supply sub
inventory and locator, if applicable, to components that have a supply type of Assembly pull or
Operation pull. You must specify a supply locator if you have mandatory locator control for the supply
sub inventory.
Supply Type: This indicates how the supply is done, options are push (material is transacated
manually), OperationPull (Backflush happens when the job is moved through operation), Assembly
Pull (Backflush happens when the assembly is completed, Supply (Material is supplied by supplier).
Mutually Exclusive and Optional: This is applicable for Model and Option class components. All
components are mandatory on Standard and Planning Bill. Pl refer the below diagram

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BOM Fixed Component
Usage
Benefits
Support for materials having fixed usage irrespective of the job size for discrete WIP job, OSFM lot-
based jobs or Flow manufacturing
Accurate valuation of assembly cost where fixed quantities of materials are used for a job

In the Basis column on the Bill of Material, a component can be set as Lot. These components
have a fixed consumption quantity for any output quantity.

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Common BOM

(N) Navigation: BOM>BOM> Tools>Common Bill

If two or more organizations manufacture the same item using the same bill of material, you
can define the bill in one organization and reference it from the other organizations. Necessary
changes must then be made to the referenced bill. You can create a common bill within the
same organization, and across multiple organizations. You have the option to create common
bills in all organizations under the current organization in the chosen organization hierarchy, or
create common bills in all organizations that have the same item master organization as the
current organization and are accessible by the user responsibility. Sharing bills across multiple
organizations minimizes the maintenance of your bills of material.
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Define BOM

Many options available from Tools menu


Create Common Bill
Check for Loops
Rollup Costs
Rollup Lead Times
..

(N) Navigation: BOM>BOM>


Tools

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Substitute

(N) Navigation:
BOM>BOM>
Substitute
You can assign any number of substitute items to each bill component and you can assign
the same substitute item to more than one component. The substitute item quantity is the
quantity needed to replace the full component quantity. The quantity can differ from the
component usage quantity.
Planning bills and model, option class, and planning components cannot have substitute
components. October 26, 2017 48
Reference Designators
(N) Navigation: BOM>BOM> Designators

Reference designators are sequenced comments and instructions that pertain to a


component. For example, you may have drawings that clarify the assembly process for
certain components, or further instructions for the use of a large quantity of the same
component. You can specify whether to assign one reference designator for every usage of
the component or assign any number of reference designators to the component.
Planning bills and model, option class, and planning components cannot have reference
designators.

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BOM Attachments
(N) Navigation: BOM>BOM> Attachments

You can attach documents to bills of material or to routing operations.


You can attach text and files, such as spreadsheets, graphics, and OLE objects to bills of
material, engineering change orders, routings, routing revisions, and routing operations.
For example, an attached file may include comments, such as a graphical representation
of the bill structure, or detailed instructions and schematic diagrams for routing
operations.
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Defining and Maintaining Lead Times Assembly : Make
Processing
Lead time

SubAssembly : Make
Cumulative Manufacturing
Lead time

Component : Buy
Cumulative Total
Lead time

Preprocessing Lead time

Processing Lead time

Postprocessing Lead time

Cumulative manufacturing lead time =


Manufacturing lead time for item +
Maximum [(cumulative manufacturing lead time for component - offset days) for
any component]

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Defining and Maintaining Lead Times
Dynamic Manufacturing Lead
Time
Oracle Engineering computes the fixed and variable portions of manufacturing
(processing) lead time using routings and detailed scheduling
Calculating processing lead time for manufactured items
Fixed lead time
Variable lead time

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Defining and Maintaining Lead Times

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Defining and Maintaining Lead Times

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Defining and Maintaining Lead Times

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Defining and Maintaining Lead Times

Result of
Lead Time
Roll Up

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Calculate Manufacturing Lead Times

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Manufacturing Scheduling

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Manufacturing Scheduling

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Manufacturing Scheduling

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Detailed Scheduling

Job Start
date / time

Op Seq 10
Res Seq 1 Res Seq 2

Res Seq 2
Op Seq 20
Res Seq 1 Res Seq 3 Res Seq 4

Op Seq 30
Res Seq 1 Res Seq 2

Scheduled = Yes

Scheduled = Next Job


Completion
Scheduled = Prior
date / time
Scheduled = No

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E- Records

Overview of Electronic Signature (e-signature) on Electronic Records (e-Records)

The Food and Drug Administration (FDA) issues new regulations for Quality Systems using
computerized software in the FDA code of Federal Regulations (CFR) Title 21 Part 11.

In general, 21 CFR Part 11 describes the requirements that must be met when using e-records and e-
signatures but does not describe where they are required. They are left to the discretion of medical
device manufacturers as where to use e-records and which e-signature to be used.

(More details are covered in the Oracle E- Records Implementation Guide).

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E- Records
CFR Part 11 and Oracle Bill of Materials
E-records and E-signatures for Oracle Bills of Material
The following table lists the Oracle Bills of Material events seeded in Oracle E-
Records.
EVENT Online or Deferred E-Signature E-Record Includes Attachment

Bill Creation Online Yes

Bill Update Online Yes

Routing Creation Online Yes

Routing Update Online Yes

Mass Change Bills Online No

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Standard Reports & Online Inquires

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Indented Bills Find Indented Bills

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Indented Bills - View

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Item Where Used

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Bill Comparison

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Bill Comparison

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Standard Reports
Bill of Material Comparison
Report
Bill of Material Listing Report
Bill of Material Loop Report
Bill of Material Structure
Report
Bill of Material Parameter
Report
Consolidated Bill of Material
Department Report
Report Item where used Report
Delete Items Report Resource Report
Resource Where used Report
Routing Report
Standard Operation Report
Workday exception sets
Report

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BOM Tables , APIs/Interfaces

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Base Tables - Oracle Bill of Materials
BOM_CALENDARS
BOM_CALENDAR_DATES
BOM_CALENDAR_EXCEPTIONS
BOM_PARAMETERS
BOM_DEPARTMENTS
BOM_RESOURCES
BOM_STRUCTURES_B
BOM_COMPONENTS_B
BOM_COMPONENT_OPERATIONS
BOM_OPERATION_RESOURCES

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ERD - BOM
MTL_SYSTEM_ITEMS_B
#INVENTORY_ITEM_ID
#ORGANIZATION_ID BOM_BILL_OF_MATERIAL
S
#BILL_SEQUENCE_ID

BOM_INVENTORY_COMPONEN
TS
#COMPONENT_SEQUENCE_ID

BOM_OPERATIONAL_ROUTING
S
#ROUTING_SEQUENCE_ID

BOM_OPERATION_SEQUENCES
#OPERATION_SEQUENCE_ID

BOM_OPERATION_RESOURC
ES
#OPERATION_SEQUENCE_ID
#RESOURCE_SEQ_NUM

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ERD - Calendar

BOM_WORKDAY_PATTERNS
#CALENDAR_CODE
#SHIFT_NUM

BOM_CALENDAR_SHIFT
BOM_CALENDAR_EXCEPTIONS
S
# CALENDAR_CODE BOM_CALENDARS
#CALENDAR_CODE
# EXCEPTION_SET_ID #CALENDAR_CODE
#SHIFT_NUM

BOM_CALENDAR_DATES
BOM_SHIFT_DATES
#CALENDAR_DATE
#CALENDAR_CODE
Other Important tables #CALENDAR_CODE
#EXCEPTION_SET_ID
BOM_CAL_WEEK_START_DAT #EXCEPTION_SET_ID
#SHIFT_DATE
ES
#SHIFT_NUM
BOM_CAL_YEAR_START_DAT
ES

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Interfaces / API - Oracle Bill of Materials
Interface Tables

BOM_BILL_OF_MATERIALS_INTERFACE
BOM_COMPONENT_OPS_INTERFACE
BOM_INVENTORY_COMPONENTS_INTERFACE
BOM_OP_RESOURCES_INTERFACE

APIs

BILL OF MATERIAL API


(Package = BOM_BO_PUB, Procedure = Process_BOM)

ROUTING API
(Package = BOM_Rtg_PUB, Procedure = Process_Rtg)

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Sample Process Analysis Questions

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Sample Process Analysis Questions
1. How do you maintain your BOM Data?

2. How many levels of BOM do you currently have?

3. How do you validate you BOM data?

4. How do you handle your BOM Changes?

5. How is your operations defined?

6. How do you validate you lead times?

7. How often the BOM Data is changed and what is Changed?

8. How does you product structure look like?

9. Is your Final Assembly demand derived based on business

strategy?

10. Do you share your resources between departments?

11. How many shifts does your business work?

12. Do you have your holiday list?

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A Simple Representation of a MODEL BOM
SCENARIO: Assembling a Computer to Customer Needs

Model = Desktop Computer

Total Levels = 3 (This is just an example)

Level 1:

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A Simple Representation of a MODEL BOM
LEVEL 2:

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A Simple Representation of a MODEL BOM
Assumptions & Explanation for Level 2:

Assumptions:

CPU is a Mandatory Item along with every computer

Key-Board is optional for the customer, but if wants to buy can only buy

either or the other.

Monitor and Mouse, are Mandatory but customer can choose his model.

Explanations:

CPU Not choosing Optional and Mutually exclusive, makes it mandatory

component in a BOM and will go along with the computer.

Key board - being a customer Optional, Optional check box is selected,

since only one model can be selected if agreed to buy, Mutually exclusive

check box is selected so that it with Joy stick is selected, the other

becomes inactive.

Monitor and Mouse Since this is mandatory along with computer, optional

box is unchecked and since he has to choose either or the other, mutually

exclusive is checked.
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A Simple Representation of a MODEL BOM
LEVEL 3:

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A Simple Representation of a MODEL BOM
Explanation for Level 3:

Monitor and Mouse are optional items, the various makes of these

components are marked as Optional.

Every option out of this BOM will be a sub-assembly or Purchased Item or

Manufactured Finished goods.

This BOM can further grow based on the customer requirements, but made short for

understanding purpose. This is just an example and help you model your actual

business requirements using these combinations.

THIS IS NOT AN END..BUT JUST A

BEGINNING

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Questions?

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End Of Presentation

TCS Internal