11.5.10 Flow Manufacturing

Oracle® Flow Manufacturing
User’s Guide
Release 11i
Part No. A69396-04
August 2004
Oracle Flow Manufacturing User’s Guide, Release 11i
Part No. A69396-04
Copyright © 1999, 2004, Oracle. All rights reserved.
Primary Author: Susan Saperstein
Contributing Authors: Valerie Dubois, Richard Rodgers, Adrian Suherman
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Contents
Send Us Your Comments ................................................................................................................... xi
Preface........................................................................................................................................................... xiii
How To Use This Guide ..................................................................................................................... xiv
Documentation Accessibility ............................................................................................................. xv
Other Information Sources ................................................................................................................. xv
Online Documentation.................................................................................................................. xvi
Related Guides ............................................................................................................................... xvi
Guides Related to All Products ................................................................................................... xvi
User Guides Related to This Product ........................................................................................ xvii
Installation and System Administration......................................................................................... xix
Other Implementation Documentation....................................................................................... xx
Training and Support .......................................................................................................................... xxi
Do Not Use Database Tools to Modify Oracle Applications Data............................................ xxii
About Oracle ................................................................................................................................. xxiii
Your Feedback............................................................................................................................... xxiii
1 Overview of Flow Manufacturing

Overview of Flow Manufacturing................................................................................................... 1-2
Demand Management........................................................................................................................ 1-3
Line Design and Balancing............................................................................................................... 1-4
Line Scheduling and Sequencing.................................................................................................... 1-6
Production Execution ......................................................................................................................... 1-8
Kanban Planning and Execution ................................................................................................... 1-10
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2 Flow Manufacturing Setup
Setup Objectives ................................................................................................................................. 2-2
Setup Steps........................................................................................................................................... 2-3
3 Line Design and Balancing Procedures

Product Synchronization ................................................................................................................... 3-2
Defining Flow Manufacturing Standard Processes ..................................................................... 3-4
Defining Flow Manufacturing Standard Events .......................................................................... 3-5
Defining Flow Manufacturing Standard Line Operations......................................................... 3-7
Flow Manufacturing Line Balance .................................................................................................. 3-8
Creating a Flow Routing.................................................................................................................... 3-9
Creating a Routing Network........................................................................................................... 3-14
Calculating Operation Times.......................................................................................................... 3-15
Operation Times Calculations........................................................................................................ 3-16
Calculating Total Product Cycle Time .......................................................................................... 3-18
Calculating Operation Yields ......................................................................................................... 3-19
Operation Yields Calculations........................................................................................................ 3-20
4 Graphical Line Designer Workbench

Overview of the Graphical Line Designer Workbench............................................................... 4-2
Navigating on the Graphical Line Designer Workbench ........................................................... 4-3
Workbench Toolbars .................................................................................................................... 4-5
Tools Menu and Pop-up Menus ................................................................................................. 4-7
Accessing Graphical Line Designer Workbench Windows........................................................ 4-9
Adding a New Item Routing .......................................................................................................... 4-18
Deleting a Routing............................................................................................................................ 4-21
Copying and Common Flow Routings ......................................................................................... 4-22
Copying a Routing to a Different Flow Line ............................................................................... 4-25
Viewing Routing Revisions ............................................................................................................ 4-27
Changing from an Alternate to a Primary Routing ............................................................... 4-28
Using the Routing Details Window .............................................................................................. 4-28
Creating the Graphical Network ................................................................................................... 4-29
Defining a Network Connection............................................................................................... 4-34
Modifying the Line Operation Tree and Process Tree ............................................................... 4-36
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Modifying Line Operations, Processes, Events, and Connections.......................................... 4-37
Creating Routings in the Template Routings View ................................................................... 4-41
Mass Changes on Item Routings ................................................................................................... 4-43
Component Assignments on the Bill of Material....................................................................... 4-49
Specifying Cost Rollup Resource Information........................................................................... 4-52
5 Mixed Model Map Workbench

Overview of the Mixed Model Map Workbench ......................................................................... 5-2
Viewing, Creating, and Updating Plans......................................................................................... 5-4
Viewing Plan Production Line and Line Operation Information ............................................. 5-7
Line Summary View..................................................................................................................... 5-8
Line Detail - Summary View....................................................................................................... 5-9
Line Detail - Resource/IPK Table View .................................................................................. 5-11
Line Detail - Graphical View .................................................................................................... 5-12
Line Operation - Detail View .................................................................................................... 5-13
Line Operation - Graphical View ............................................................................................. 5-14
Viewing Item Details for a Line................................................................................................ 5-16
Viewing Plan Resource Information............................................................................................. 5-16
Resource Assignment....................................................................................................................... 5-21
In Process Kanban Assignment ..................................................................................................... 5-22
Filtering and Sorting Information................................................................................................. 5-24
6 Flow Sequencing
Overview of Flow Sequencing......................................................................................................... 6-2
Setting Up Flow Sequencing ............................................................................................................ 6-4
Viewing and Defining Sequencing Attributes ............................................................................. 6-8
Viewing Sequencing Rules............................................................................................................. 6-10
Defining Sequencing Rules and Constraints.............................................................................. 6-13
Viewing and Updating Production Lines .................................................................................... 6-16
Assigning Production Lines and Rules ........................................................................................ 6-19
Creating Sequencing Tasks............................................................................................................. 6-22
Entering Sequencing Task Parameters .................................................................................... 6-23
Selecting Production Lines for a Task ..................................................................................... 6-24
Filtering Demands for a Sequencing Task .............................................................................. 6-25
Viewing Results and Submitting a Sequencing Task ............................................................ 6-26
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Updating Line Task Parameters ............................................................................................... 6-28
Moving Demand ......................................................................................................................... 6-31
Updating Demands .................................................................................................................... 6-32
Splitting Demands ...................................................................................................................... 6-33
Resequencing Tasks ......................................................................................................................... 6-34
Viewing Sequencing Tasks ............................................................................................................. 6-34
Sequencing Task Summary ....................................................................................................... 6-36
Sequencing Task Details and Results ........................................................................................... 6-37
7 Line Scheduling Workbench

Overview of Line Scheduling Workbench in Flow Manufacturing ......................................... 7-2
Defining Scheduling Rules .............................................................................................................. 7-3
Scheduling Rule Options ............................................................................................................. 7-3
Scheduling Algorithms ................................................................................................................ 7-4
Sequencing Criteria ...................................................................................................................... 7-4
Define Scheduling Rules Window ............................................................................................. 7-5
Line Scheduling Workbench Options Window............................................................................ 7-8
Viewing Unscheduled Orders ........................................................................................................ 7-10
Linking Sales Orders to Schedules ........................................................................................... 7-13
Viewing, Creating, and Modifying Flow Schedules.................................................................. 7-14
Creating Flow Schedules ........................................................................................................... 7-15
Flow Schedule Summary Window .......................................................................................... 7-18
Flow Schedule Details Window................................................................................................ 7-20
How Scheduling is Calculated ....................................................................................................... 7-23
Algorithms ................................................................................................................................... 7-23
Line Scheduling Workbench Tools Menu.................................................................................... 7-25
Completion of Flow Schedules ................................................................................................. 7-25
Mixed Model Map ...................................................................................................................... 7-25
Roll Flow Schedules ................................................................................................................... 7-25
Deleting Flow Schedules............................................................................................................ 7-29
Preferences ................................................................................................................................... 7-31
Other Features ................................................................................................................................... 7-32
Component Availability ............................................................................................................ 7-32
Purging Flow Schedules ............................................................................................................ 7-33
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8 Feeder Line Synchronization
Feeder Line Synchronization............................................................................................................ 8-2
9 Outbound Broadcast Sequencing

Overview of Outbound Broadcast Sequencing ............................................................................ 9-2
Setting Up Outbound Broadcast Sequencing ............................................................................... 9-2
Process Flow......................................................................................................................................... 9-3
10 Flow Execution Workstation

Overview of the Flow Execution Workstation ............................................................................ 10-2
Setting Your Preferences ................................................................................................................. 10-2
Initializing the Flow Execution Workstation .............................................................................. 10-8
Work Queue Mode ................................................................................................................... 10-10
User Entered Mode................................................................................................................... 10-12
Viewing Schedule Information.................................................................................................... 10-13
Viewing Event Information .......................................................................................................... 10-15
Completing Line Operations........................................................................................................ 10-16
Completing Schedules................................................................................................................... 10-19
Viewing Resources ......................................................................................................................... 10-20
Attaching and Viewing Instructions........................................................................................... 10-21
Viewing Detail Properties............................................................................................................. 10-25
Viewing Components and Replenishing Kanban Cards........................................................ 10-26
Integration with Oracle Quality .................................................................................................. 10-27
Customized Properties Region..................................................................................................... 10-28
Engineering Change Order Alerts............................................................................................... 10-28
11 Graphical Kanban Workbench

Overview of the Graphical Kanban Workbench ........................................................................ 11-2
Navigating on the Graphical Kanban Workbench..................................................................... 11-2
Color Representation ................................................................................................................. 11-2
Workbench Toolbar.................................................................................................................... 11-3
Tools Menu and Pop-up Menus ............................................................................................... 11-3
Accessing the Production Region .................................................................................................. 11-5
Adding an Item to the Tree ............................................................................................................. 11-9
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Modifying and Creating Pull Sequences on the Graphical Network .................................. 11-10
Pull Sequence Window.................................................................................................................. 11-12
Using a Template to Create a Pull Sequence ............................................................................. 11-14
Accessing the Planning Region.................................................................................................... 11-19
Viewing Kanban Demands ........................................................................................................... 11-25
Changing and Viewing Kanban Details .................................................................................... 11-25
Viewing and Changing Summary Pull Sequences .................................................................. 11-29
Launching a Kanban Plan ............................................................................................................. 11-34
Updating Production ...................................................................................................................... 11-34
Purging Kanban Cards and Pull Sequences .............................................................................. 11-37
12 Reports and Processes

Schedule Report ................................................................................................................................ 12-2
Linearity Report ................................................................................................................................ 12-4
A Windows and Navigation Paths

Windows and Navigator Paths ......................................................................................................... A-2
B Line Scheduling Calculation Examples

Scheduling Calculations and Examples ......................................................................................... B-2
Roll Flow Schedules ........................................................................................................................... B-4
Tolerance Fences.................................................................................................................................. B-4
Schedule Completion Time ......................................................................................................... B-5
Feeder Line Synchronization Calculations .................................................................................... B-5
C Mixed Model Map

Overview of Mixed Model Map ...................................................................................................... C-2
Entering Mixed Model Map Parameters ........................................................................................ C-2
Generating a Mixed Model Map...................................................................................................... C-4
Saving a Baseline ............................................................................................................................... C-7
Querying a Saved Baseline .............................................................................................................. C-8
Placing a Mixed Model Map on the Navigator ............................................................................. C-9
Mixed Model Map Calculations ................................................................................................... C-10
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D Mixed Model Map Workbench Calculations
Mixed Model Map Workbench Calculations ................................................................................ D-2
Glossary
Index
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Send Us Your Comments
Oracle Flow Manufacturing User’s Guide, Release 11i
Part No. A69396-04
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Preface
Welcome to the Oracle Flow Manufacturing User’s Guide, Release 11i.

This guide assumes you have a working knowledge of the following:
■ The principles and customary practices of your business area.
■ Oracle Flow Manufacturing.
If you have never used Oracle Flow Manufacturing, Oracle suggests you
attend one or more of the Oracle Applications training classes available
through Oracle University.
■ Oracle Self-Service Web Applications.
To learn more about Oracle Self-Service Web Applications, read the Oracle
Self-Service Web Applications Implementation Manual.
■ The Oracle Applications graphical user interface.
To learn more about the Oracle Applications graphical user interface, read the
Oracle Applications User’s Guide.
See Other Information Sources for more information about Oracle Applications
product information.
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How To Use This Guide
The Oracle Flow Manufacturing User’s Guide contains the information you need to
understand and use Oracle Flow Manufacturing. This guide contains a preface, ten
chapters, and three appendices:
■ Preface: Explains how this user guide is organized and introduces other sources
of information that can help you.
■ Chapter 1: Provides an overview of the features in Flow Manufacturing.

■ Chapter 2: Describes how to set up Flow Manufacturing.
■ Chapter 3: Describes Flow Manufacturing line design, and operation yields and
calculations.
■ Chapter 4: Describes the Graphical Line Designer Workbench functionality and
setup tasks.
■ Chapter 5: Describes the Mixed Model Map Workbench functionality and its
use in designing a balanced production.
■ Chapter 6: Describes Flow Sequencing, the process of determining when items
are built on the production line for creating Flow schedules.
■ Chapter 7: Describes the functionality in the Line Scheduling Workbench
including creating flow lines and scheduling algorithms.
■ Chapter 8: Provides an overview of feeder line synchronization, a process that
calculates the date and time the subassembly is delivered to the particular line
operation.
■ Chapter 9: Describes Outbound Broadcast Sequencing—a process enabling the
creation of replenishment signals on a Flow line for special supplier
requirements.
■ Chapter 10: Describes the Flow Execution Workstation, used to track the flow of
shop floor work, and complete schedules.
■ Chapter 11: Describes the Graphical Kanban Workbench functionality which
combines kanban setup, kanban planning, pull sequence definition, and
planning simulation.
■ Chapter 10: Describes Oracle Flow Manufacturing Reports.
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■ Appendices:
■ Details the default navgator path for each Oracle Flow Manufacturing
window
■ Line Scheduling calculation examples
■ Provides information on the Mixed Model Map window
■ Mixed Model Map Workbench calculations
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Other Information Sources

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Oracle Flow Manufacturing.
If this guide refers you to other Oracle Applications documentation, use only the
Release 11i versions of those guides.
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Online Documentation
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Related Guides
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Oracle Applications products. Therefore, you may want to refer to other guides
when you set up and use Oracle Flow Manufacturing.
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Guides Related to All Products
Oracle Applications User’s Guide

This guide explains how to enter data, query, run reports, and navigate using the
graphical user interface (GUI). This guide also includes information on setting user
profiles, as well as running and reviewing reports and concurrent processes.
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You can access this user’s guide online by choosing “Getting Started with Oracle
Applications” from any Oracle Applications help file.
User Guides Related to This Product
Oracle Advanced Planning Implementation and User’s Guide

This guide describes how to use Oracle’s supply chain planning performance for
forecasting and managing both supply and demand for your items. You plan your
requirements, and execute and release the plan for discrete jobs, repetitive
schedules, and flow schedules.
Oracle Bills of Material User’s Guide

This guide describes how to create various bills of materials to maximize efficiency,
improve quality and lower cost for the most sophisticated manufacturing
environments. By detailing integrated product structures and processes, flexible
product and process definition, and configuration management, this guide enables
you to manage product details within and across multiple manufacturing sites.
Oracle Cost Management User’s Guide

This guide describes how to use Oracle Cost Management in either a standard
costing or average costing organization. Cost Management can be used to cost
inventory, receiving, order entry, and work in process transactions. It can also be
used to collect transaction costs for transfer to Oracle Projects. Cost Management
supports multiple cost elements and multiple subelements. It also provides
comprehensive valuation and variance reporting.
Oracle General Ledger User’s Guide

This guide explains how to plan and define your chart of accounts, accounting
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journal entries for your general ledger. If you use multiple currencies, use this
manual when you define additional rate types, and enter daily rates. This manual
also includes complete information on implementing Budgetary Control.
Oracle Inventory User’s Guide

This guide describes how to define items and item information, perform receiving
and inventory transactions, maintain cost control, plan items, perform cycle
counting and physical inventories, and set up Oracle Inventory.
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Oracle Master Scheduling/MRP and Oracle Supply Chain Planning User’s
Guide
This guide describes how to anticipate and manage both supply and demand for
your items. Using a variety of tools and techniques, you can create forecasts, load
these forecasts into master production schedules, and plan your end-items and their
component requirements. You can also execute the plan, releasing and rescheduling
planning suggestions for discrete jobs, repetitive schedules, and flow schedules.
Oracle Order Management User’s Guide

This guide describes how to enter sales orders and returns, copy existing sales
orders, schedule orders, release orders, create price lists and discounts for orders,
run processes, and create reports.
Oracle Purchasing User’s Guide

This guide describes how to create and approve purchasing documents, including
requisitions, different types of purchase orders, quotations, RFQs, and receipts. This
guide also describes how to manage your supply base through agreements,
sourcing rules and approved supplier lists. In addition, this guide explains how you
can automatically create purchasing documents based on business rules through
integration with Oracle Workflow technology, which automates many of the key
procurement processes.
Oracle Quality User’s Guide

This guide describes how Oracle Quality can be used to meet your quality data
collection and analysis needs. This guide also explains how Oracle Quality
interfaces with other Oracle Manufacturing applications to provide a closed loop
quality control system.
Oracle Work in Process User’s Guide

This guide describes how Oracle Work in Process provides a complete production
management system. Specifically this guide describes how discrete, repetitive,
assemble-to-order, project, flow, and mixed manufacturing environments are
supported.
xviii
Installation and System Administration
Oracle Applications Concepts
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Oracle applications file system and database.
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Oracle Applications System Administrator’s Guide
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Oracle Alert User’s Guide

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Other Implementation Documentation
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changes made to database objects, profile options, and seed data for this interval.
Multiple Organizations in Oracle Applications

This guide describes how to set up and use Oracle Flow Manufacturing with Oracle
Applications' Multiple Organization support feature, so you can define and support
different organization structures when running a single installation of Oracle Flow
Manufacturing.
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Oracle Workflow Guide
This guide explains how to define new workflow business processes as well as
customize existing Oracle Applications-embedded workflow processes.You also use
this guide to complete the setup steps necessary for any Oracle Applications
product that includes workflow-enabled processes.
Oracle Applications Flexfields Guide

This guide provides flexfields planning, setup and reference information for the
Oracle Flow Manufacturing implementation team, as well as for users responsible
for the ongoing maintenance of Oracle Applications product data. This manual also
provides information on creating custom reports on flexfields data.
Oracle eTechnical Reference Manuals

Each eTechnical Reference Manual (eTRM) contains database diagrams and a
detailed description of database tables, forms, reports, and programs for a specific
Oracle Applications product. This information helps you convert data from your
existing applications, integrate Oracle Applications data with non-Oracle
applications, and write custom reports for Oracle Applications products. Oracle
eTRM is available on OracleMetaLink
Oracle Manufacturing APIs and Open Interfaces Manual

This manual contains up-to-date information about integrating with other Oracle
Manufacturing applications and with your other systems. This documentation
includes APIs and open interfaces found in Oracle Manufacturing.
Oracle Applications Message Reference Manual

This manual describes all Oracle Applications messages. This manual is available in
HTML format on the documentation CD-ROM for Release 11i.
Training and Support

Training
Oracle offers a complete set of training courses to help you and your staff master
Oracle Flow Manufacturing and reach full productivity quickly. These courses are
organized into functional learning paths, so you take only those courses appropriate
to your job or area of responsibility.
You have a choice of educational environments. You can attend courses offered by
Oracle University at any one of our many education centers, you can arrange for
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our trainers to teach at your facility, or you can use Oracle Learning Network
(OLN), Oracle University's online education utility. In addition, Oracle training
professionals can tailor standard courses or develop custom courses to meet your
needs. For example, you may want to use your organization structure, terminology,
and data as examples in a customized training session delivered at your own
facility.
Support
From on-site support to central support, our team of experienced professionals
provides the help and information you need to keep Oracle Flow Manufacturing
working for you. This team includes your technical representative, account
manager, and Oracle’s large staff of consultants and support specialists with
expertise in your business area, managing an Oracle server, and your hardware and
software environment.
Do Not Use Database Tools to Modify Oracle Applications Data

Oracle STRONGLY RECOMMENDS that you never use SQL*Plus, Oracle Data
Browser, database triggers, or any other tool to modify Oracle Applications data
unless otherwise instructed.
Oracle provides powerful tools you can use to create, store, change, retrieve, and
maintain information in an Oracle database. But if you use Oracle tools such as
SQL*Plus to modify Oracle Applications data, you risk destroying the integrity of
your data and you lose the ability to audit changes to your data.
Because Oracle Applications tables are interrelated, any change you make using
Oracle Applications can update many tables at once. But when you modify Oracle
Applications data using anything other than Oracle Applications, you may change a
row in one table without making corresponding changes in related tables. If your
tables get out of synchronization with each other, you risk retrieving erroneous
information and you risk unpredictable results throughout Oracle Applications.
When you use Oracle Applications to modify your data, Oracle Applications
automatically checks that your changes are valid. Oracle Applications also keeps
track of who changes information. If you enter information into database tables
using database tools, you may store invalid information. You also lose the ability to
track who has changed your information because SQL*Plus and other database
tools do not keep a record of changes.
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About Oracle
Oracle develops and markets an integrated line of software products for database
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project systems, human resources and customer relationship management.
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services, in over 145 countries around the world.
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1
Overview of Flow Manufacturing
This chapter will give you an overview of the features contained in Oracle Flow
Manufacturing, including:
■ Overview of Flow Manufacturing on page 1-2
■ Demand Management on page 1-3
■ Line Design and Balancing on page 1-4
■ Line Scheduling and Sequencing on page 1-6
■ Production Execution on page 1-8
■ Kanban Planning and Execution on page 1-10
Overview of Flow Manufacturing 1-1


Flow Manufacturing is a manufacturing approach employing the following
practices:
■ Building to customer demand rather than building to a forecast
Reduces finished goods inventories, reduces cost, and increases customer
satisfaction.
■ Linear manufacturing rather than batch production
Reduces work in process inventory, rework, and scrap and increases product
quality as quality and assembly problems are immediately addressed.
■ Mixed model production rather than process layout
Enables a mix of products to be produced on one production line in the same
day, which allows the manufacturer to respond to the demand generated by
customer orders.
■ In-process quality rather than inspecting quality into the product after assembly
Builds quality into the product during the production process resulting in less
rework, less scrap, lower cost, and higher customer satisfaction.
■ JIT Replenishment of component materials rather than receipts of MRP
forecasted demands.
Reduces the amount of component inventory and reduces costs.
■ Uses rate-based production rather than work orders
Simplifies shop floor activities and reduces cost.
■ Labor flexibility rather than labor specialization
Increases productivity and reduces costs.
■ Backflush material and costs upon completion rather than at each operation
Simplifies shop floor activities and reduce costs.
Oracle Flow Manufacturing includes a comprehensive set of features that support
the entire flow process from line design and balancing to production execution. It
enables implementation of the demand pull system using kanbans for both raw
material and in-process assemblies. The planning process is streamlined using Flow
schedules to sequence and schedule mixed model production.
1-2 Oracle Flow Manufacturing User’s Guide

Demand Management
The features provided by Oracle Flow Manufacturing are classified into the
following categories:
■ Demand Management on page 1-3
■ Line Design and Balancing on page 1-4
■ Line Scheduling and Sequencing on page 1-6
■ Production Execution on page 1-8
■ Kanban Planning and Execution on page 1-10
Demand Management
Demand management is a factor during both the initial design of flow production
lines and the daily execution of the rate-based schedules. During the design phase,
the objectives of demand management are to group similar products into families,
which allows for planning at an aggregate level and to develop a peak daily volume
for all products that will be used for line balancing and kanban planning. During
production execution, the objectives are to increase responsiveness to customer
demand and to maximize resource use.
Oracle Flow Manufacturing uses the demand management tools provided in Oracle
MPS/MRP, Supply Chain Planning and Advanced Planning and Scheduling to plan
production volumes.
Line Design
Line design is based upon the anticipated demand for a product or product family.
This anticipated demand represents the peak daily volume. All production
resources, machines, and labor are then calculated based on these volumes.
Additionally, these demand figures and factory schedule hours are used to derive
the takt time, or rate that products must be produced to meet the schedule. This
figure represents the rate that products must leave the end of the line in order to
meet customer demand. See: Product Synchronization on page 3-2
Kanban Planning
Oracle Flow Manufacturing uses a kanban pull replenishment system to signal
material requirements and pull material from its defined source as needed to meet
daily customer demand. The objective of the kanban replenishment system is to
continuously improve the production with zero stock outs, shorter lead times,
reduced inventory, and minimal supervision. The statement of demand used to
balance flow lines to peak daily demand is generally used size kanbans of

Line Design and Balancing
components. The use of a MPS or MRP plan for kanban items gives visibility to the
long term plan. This plan is then communicated to trading partners, including
marketing and suppliers.
In Oracle Flow Manufacturing, any number of baseline and simulation kanban
plans can be created in which kanban quantities for each item or kanban location
can be calculated and stored. Optimal kanban quantities can be calculated for the
desired demand schedule.
Production Execution
In a flow manufacturing environment, daily production rates tend to be based on
customer demand, including marketing orders. Flow lines are balanced with
machines and resources to produce at the takt needed to meet the peak daily
volume. By design, the daily customer demand should be less than that peak,
ensuring that customer demand will be met. However, the mixed and demand
represented in daily customer orders are not necessarily in the same ratios as the
peak daily volumes design for. To manage the demand fluctuations, Oracle Flow
Manufacturing uses simple flow schedules to schedule and sequence sales orders.

Line design and balancing is the foundation of a flow production line. The objective
is to balance lines for mixed model production at the expected peak demand that
take the least possible time to execute. This is accomplished through flat product
structures and simple processes which can be communicated visually to meet
customer demand daily. Line design includes grouping products into product
families, defining the processes and events required to produce each product, and
re-grouping events into line operations to approximate takt time.
Effective flow line design and balanced production smoothes production and
eliminates bottlenecks. Flow lines are designed to reduce production time and
resource costs by identifying value add events and eliminating non-value events.
Simplified processes are designed to reduce overhead costs by optimizing floor
space utilization. This simplified design also helps increase communication on the
production floor through visual management tools. Quality is improved by
implementing quality into the process, instead of inspecting in at the end.
Product Synchronization
Product synchronization defines the processes used to make each product and the
sequence of events within each process. Events are granular tasks within the

process that define the physical activities on the line. Each event is assigned the
machine and labor times used to perform the event.
Product synchronization tasks are performed in Oracle Flow Manufacturing using
flow routings. Flow routings support both processes and sequence of events. In
addition flow routings can be used to define the network of processes including
feeder lines, rework loops, and both primary and alternate processes required to
produce an item. This will help model the line as is to the system. Flow routings
and the routing network are also used to calculating the total product cycle time.
Total product cycle time is the longest time path on the production line, including
feeder lines, required to make the product.
See Also
Creating a Routing, Oracle Bills of Material User’s Guide.
Product Synchronization on page 3-2
Mixed Model Map Workbench

The Mixed Model Map Workbench is used to achieve balanced flow lines. The
Mixed Model Map Workbench combines the information from the products
assigned to a specific line—including their routing, product family grouping, and
forecasted demand. This information is displayed in a graphical interface.The takt
time is calculated from the daily production requirements (demand) and the
available production hours in a day. The summary portion of the Mixed Model Map
displays the machine and labor resources needed to meet the takt time. Since takt
time establishes the rhythm of the line, all the processes along the line are
streamlined to complete within the takt time. This ensures that each product moves
from process to process within the takt time, which maintains the steady production
rate necessary to meet the demand. See: Overview of Mixed Model Map Workbench
on page 5-2
Line Balancing
While engineering provides information on product routings in the form of
processes and sequence of events, manufacturing faces the challenge of organizing
work on a production line so that bottlenecks are minimized and work cells are
balanced. As a result, manufacturing evaluates the feasibility of reorganizing the
events into groups that approximate takt time. Managing the imbalances leads to
analysis for the following:
■ Reducing or eliminating non-value-added work
■ Using smaller units for the work, or grouping into larger units

Line Scheduling and Sequencing
■ Increasing resource (machine, labor) capacity

■ Increasing in-process inventory
■ Adding additional lines
Once the current line has been set up with items, organizations, the flow line, a
forecast, and the product routings defined, the line can be balanced through
iterative processes using the Graphical Line Designer Workbench. See: Accessing
Graphical Line Designer Workbench Windows on page 4-9
Operation Method Sheets

Operation Method Sheets (OMS) provide the needed information to shop floor
personnel for performing an operation on the line. This information can include
pictures of the assembly process, required materials, and written work instructions.
These are the primary tools used to perform the operations and are especially
critical on lines making many models.
Oracle Flow Manufacturing supports Operation Method Sheets using the
Attachments feature. Multimedia documents can be attached to, and maintained
for, each line operation on the flow routing of each item.

In flow manufacturing, line scheduling is equal to line design and balancing in
terms of importance. A line well designed to meet average daily demand that is
scheduled improperly can cause excessive change-over, large peaks in demand to
kanbans, or unbalanced demand on resources. Each of these will undermine the
line’s ability to perform to takt. Oracle Flow Manufacturing allows for the creation
and use of simple scheduling rules to schedule either sales or planned orders for the
flow line. The objective of line scheduling is to sequence production to maximize
resource utilization and minimize delays.
Line scheduling allows for:
■ Creation of a scheduling rule based on pre-defined sequencing criteria and
scheduling algorithms
■ Viewing of all unscheduled orders for your line and choose which orders you
want to schedule
■ Scheduling the line and viewing the final flow schedule.
Scheduling rules determine the logic used to create flow schedules from orders.
They are a combination of sequencing criteria and scheduling algorithms that can

help you pull demand forward or backward in time, in order to meet takt for each
day.
Scheduling Algorithms
Scheduling algorithms are used to smooth demand by restricting the number of
each assembly that is scheduled in any given day. Demand smoothing is important
because the line is designed based on an average daily mix. However, seldom if
ever will a line produce exactly the mix for which it was designed. Demand
smoothing ensures that the mix is maintained as closely as possible, which helps the
line to operate more efficiently and achieve takt time on a daily basis.
Note: Line Scheduling does not schedule a portion of a product:

the algorithm rounds decimal quantities up to whole units before
scheduling.
Sequencing Criteria
Sequencing criteria is used to determine the priority in which sales orders are
scheduled.
Flow Manufacturing Sequencing and Execution

Sequencing is the process of determining the order assembly items are built on a
production line. Attributes, constraints, rules, are used in your production lines to
create sequencing tasks. The sequence assembly items are built determines the
efficiency of the line, and therefore, the productivity of the manufacturing
organization. The Sequencing pages enable you to set up task components, generate
tasks, and view the results. The Flow Sequencing concurrent program takes the
sequencing task as input, and creates Flow schedules to meet production demands.
See Also
Overview of Line Scheduling Workbench in Flow Manufacturing on page 1-2
Line Scheduling Workbench Options Window on page 7-8
How Scheduling is Calculated on page 7-23
Overview of Flow Sequencing on page 6-2
Creating Sequencing Tasks on page 6-22

As through-put time and inventory levels are driven down during implementation
of Oracle Flow Manufacturing, the need for and value of detailed production
information becomes less critical. This creates the opportunity to eliminate or
streamline production execution transactions. One of the tools provided by Oracle
Flow Manufacturing to help in this process is the Work Order-less Completion
transaction.

The Mixed Model Map Workbenchis the tool that Oracle Flow Manufacturing uses
to achieve balanced flow lines. After lines have been designed and during the
production cycle, the Mixed Model Map becomes a tool to evaluate the impact of
the current production schedule on the resources, operational times and in-process
kanbans. In this mode, the summary portion of the Mixed Model Map displays the
machine and labor resources needed to meet the takt time for the current
production load. The baseline comparison highlights where labor resources can be
removed to allow for flexing and where extra resources or overtime may be needed
to produce to demand. See: Overview of the Mixed Model Map Workbench on
page 5-2
Work Order-Less Completions

Production is recorded with the Work Order-less Completion transaction against
flow schedules created with the Line Scheduling Workbench. Completions can be
either unscheduled or scheduled against a flow schedule. The system backflushes
all components and performs resource and overhead transactions upon recording
completion of the finished product. Additionally, Oracle Flow Manufacturing
allows assembly completions to be recorded without having to create work orders, a
job or repetitive schedule, or a flow schedule.
Work order-less completions do the following:
■ Backflush pull and push components
■ Charge resources and overhead based on the flow routing
See: Work Order-less Completions, Oracle Work in Process User’s Guide
Manufacturing Costing
The costing method of the organization determines whether mixed manufacturing
methods can be used. Costing in a flow environment is usually done using standard
costing methods. Average costing may also be used, particularly when used in

conjunction with project manufacturing. Cost variances are collected and posted
during the Work Order-less Completion transaction.
Component Picking
You can perform component picking transactions for flow schedules using the rules
based system in Oracle Warehouse Management. Flow manufacturing
environments use kanban signals to control the replenishment of components on
the line. However, the picking functionality can be used for slower moving or
randomly used planned components to create move orders for supply push
components. The Component Pick Release window is used to select requirements
and create move orders. It is a graphical workbench that displays fields applicable
to the job or schedule type accessed. The features in component picking for flow
schedules include:
■ There is a distinct Component Pick Release window for the Flow
Manufacturing mode.
■ The source for material picked is based on Oracle Inventory allocation rules
entered on the Picking Rules window. Or, if Oracle Warehouse Management is
installed, rules based picking recommendations.
■ Material must be defined at a valid line operation.
■ The status of the line must be Open.
■ Move orders are generated when all quantities for the flow schedule
components can be filled.
■ Components must be a supply type of Push.
■ Move orders are only generated when the flow schedule components can be
filled. If the components are not on-hand, backorders are not created.
■ You can run the pick release multiple times until the requirement is filled since
move orders are not generated for flow schedules with component shortages.
See Also
Overview of Component Picking, Oracle Work in Process User’s Guide
Navigating on the Component Pick Release Window, Oracle Work in Process User’s
Guide
Using the Component Pick Release Window, Oracle Work in Process User’s Guide

Kanban Planning and Execution
Flow Execution Workstation

The Flow Execution Workstation provides features for tracking the flow of work,
completing assemblies, and viewing detail information. You can view Flow
schedules, line operations and their corresponding event sequences, components,
resources, and instructions. The workstation enables you to complete schedules and
line operations, customized your display of information, and check for eligible
engineering change orders (ECOs). See: Initializing the Flow Execution Workstation
on page 10-8

A key objective of flow manufacturing and JIT production is to minimize inventory
and increase inventory turns. Raw material is pulled into production as needed to
meet demand and the pulled material is replenished using a kanban signal. The
minimum amount of material possible, based on replenishment time is held at the
line in kanban bins. As each bin is emptied, a signal is issued to replenish the bin
and the next bin is used to pull the material.
There are many kanban systems in use today but the most commonly used are (i)
the two-bin (two card) system and (ii) multi-bin (multi card) system. Oracle Flow
Manufacturing supports both these systems for planning and execution during
production.
Calculation of Kanban Size and Number of Cards

Oracle Flow Manufacturing calculates the optimal number of kanbans needed in
each kanban location. It can calculate the number of kanbans needed when a bin
quantity is specified or it can calculate the kanban size if the number of bins are
specified. Oracle Flow Manufacturing allows the simulation of multiple kanban
plans. Kanbans currently in use can be compared and adjusted against kanban
requirements for consistently varying demands. This process helps in both
maintaining minimal material inventory and continuity of material flow from the
supplier to the production line.
Pull Sequences
Oracle Flow Manufacturing helps you define the kanban locations for each item
along with the supply source information. The supply source can be suppliers,
other production lines, other inventory organizations in the enterprise, or other
kanban locations in the same organization. A complete chain of demand-supply
pull sequences can be defined for kanban planning.

Non-Replenishable Kanbans
Non-replenishable kanbans are used to meet unexpected peaks in demand. For
demand variations that are infrequent and unplanned, Oracle Flow Manufacturing
allows non-replenishable kanban cards. These cards are created for specific items in
specific quantities as needed. Non-replenishable kanbans cycle through the system
only once, after which they are removed from production.
Kanban Execution
Oracle Flow Manufacturing generates appropriate events for each kanban signal.
For kanbans that are sourced through suppliers, the system can generate
requisitions and purchase orders. Sourcing rules can also be used to create blanket
releases against purchase contracts. Internal requisitions can be generated for
inter-organization replenishments.
Oracle Flow Manufacturing supports different statuses of kanban cards to help
track their release cycle. Supported statuses include Full, Empty, In-Process,
In-Transit, Hold, and others. Kanban Cards can also be accumulated and released
together when a minimum order quantity greater than the kanban size is specified.
A number of modifiers such as safety stock days and lot multiplier allow you to
create a smooth signaling and replenishment system.
See Also
Pull Sequence Window on page 11-12.
Modifying and Creating Pull Sequences on the Graphical Network on page 11-10


2
Flow Manufacturing Setup
This chapter describes the processes involved in setting up Oracle Flow

Manufacturing, including:
■ Setup Objectives on page 2-2
■ Setup Steps on page 2-3
Flow Manufacturing Setup 2-1

Setup Objectives
Setup Objectives
Setting up Oracle Flow Manufacturing follows the business process for a flow
implementation, and relates directly to the tasks performed in the implementation.
The sequence the tasks are performed is important in relationship to data
dependencies.
Note: For detailed instruction and data field considerations, see:

Oracle Flow Manufacturing Implementation Manual.
Oracle Flow Manufacturing setup steps are classified into logical groups, and
assigned to business processes to achieve specific implementation objectives. These
include:
Setup Prerequisites
■ Naming Convention Definition
■ Profile Options
■ Organizations
■ Item Flexfields
■ Inventory Parameters
■ Cost Accounts Creation for Work in Process costing
■ Subinventories creation for flow lines
■ Bills of Material Parameters
■ Purchasing Setup for suppliers and purchasing functionality
■ Order Management Setup for sales orders
Item Templates
■ Flow Finished Goods Template, or Flow Assembly—used to define the standard
template for creation of Finished Goods items.
■ Flow Component Template—used to define the standard template for creation
of Flow Components items. A Flow Component can be Buy, Make, or Phantom.

Setup Steps
Demand Management
■ Products and Parts—defines the products and parts to be produced, and groups
them to facilitate demand forecasting and production assembly.
■ Bills of Material—creates a bill of materials for the products and parts to include
their family relationship, location in the flow line, and the source of their
supply.
■ Planning—used to identify and create the appropriate planning tools which
apply expected demand to the product family structures, item demand
locations and item supply locations for calculating the flow line capacity and
rates.

■ Flow Line—defines the flow lines, production resources and departments.
■ Product Synchronization—defines the activities and processes in the flow line,
and balance the resources and processes to meet demand.
Line Scheduling
Define your scheduling rules
Work Order-less Production—to meet daily production requirements.

Define the flow line’s replenishment chain for execution of the requested material,
just in time, in the expected quantity to the place it is needed.
Setup Steps
Demand Management
In designing a flow line, a company analyzes the market forecast for the products
and takes a look at the long term forecast. Since production planning occurs at the
aggregate level, creating a production plan involves grouping products into product
families. These groupings are based on product’s similarities in design,
manufacturing process, and resource usage.

Setup Steps
In demand management you can assign planning percentages to members of the

product family, and use the relationship between a product family item and its
members in:
■ Forecast explosion
■ Consumption
■ Master Scheduling
■ Capacity and Materials Planning
In production planning you can explode product family forecasts down to the
product family members—based on the planning percentages and effectivity dates
for the member items.
Sales orders for member items consume the forecast for the member items as well as
for the product family. Throughout the application, processing is done at both the
aggregate and detail level. The setup objectives of demand management and
production planning are achieved through the successful implementation of:
■ Products and Parts Setup
■ Bills of Material Setup
■ Planning Setup
❏ Products and Parts
The objectives of products and parts setup are to create both finished goods and
component items, and to group the products and parts in logical product
families. This facilitates demand forecasting and production assembly. To
implement Oracle Flow Manufacturing it necessary to set up:
■ Items
■ Product Families
■ Product Family Members
■ Categories and Category Sets
❏ Bill of Materials
The objective of bill of materials setup is to create a bill of material for the
products and parts, and to assign a subinventory to each item in the bill of
material. The fundamental setup requirement for Oracle Flow Manufacturing is
that the subinventory assigned in the pull sequence for an item matches with
the subinventory assigned in the bill of material or item master for the same
item. Pull sequences are defined in kanban planning and execution.

Setup Steps
❏ Planning
The setup objectives of planning are to identify and create the appropriate
planning tools to apply expected demand to the product family structures, item
demand locations, and item supply locations. This is used to calculate the Flow
line capacity and rates. To implement Oracle Flow Manufacturing it necessary
to set up planning capabilities:
■ Forecasting
■ Master Demand Schedules

In a Flow Manufacturing environment, products are produced on a flow line to
meet customer demand. Typically one flow line makes a mix of products. The exact
mix depends on how much flex is built into the line design. Factors that determine
flex include employees certified to work multiple processes (operations,) and
machines that perform more than one function. You can define and update, but not
delete, production lines. A production line describes a unique set of processes or
line operations that produce one or more of your products. You can associate
production lines with work order-less completions.
In line design and balancing, you define items and inventory organizations, create
the flow line, and set up the production synchronization tools to balance the line.
The setup objectives of line design and balancing are achieved through the
successful implementation of:
■ Items and Organizations
■ Flow Lines
■ Product Synchronization
❏ Flow Line Setup
The flow line is an organization of resources and departments. Once the flow
line is defined, processes and activities (events) are applied to create operations
on the flow line. Oracle Flow Manufacturing provides a planning tool, the
Mixed Model Map Workbench, to calculate process times and volumes to
balance resources and events—and optimize flow line efficiency.

Setup Steps
To implement Oracle Flow Manufacturing it necessary to set up:

■ Flow Lines
■ Resources
■ Departments
❏ Product Synchronization
Product synchronization is an approach to defining the processes, and sequence
of events within each process, to manufacture a product. The objectives of
product synchronization are to organize the flow line activities and processes.
This is performed while balancing the resources to schedule smooth production
while meeting daily demand. After you have defined the organizations,
departments, resources and items to be produced on the flow line, you:
■ Identify the route each item moves towards completion
■ Produce a Mixed Model Map to balance the resources and processes to meet
demand
In order to implement these objectives, define and set up:
■ Standard Events
■ Standard Processes
■ Flow Routings
■ Standard Operations
❏ Event and Resource Functions in a Standard Processes Example
This example illustrates the relationship of Standard Processes, Resources and
Events. A line worker has two work events to perform to install handle bars on
a bike—mount bar to frame, and bolt it to the frame
The standard process is to Install Handle Bars. The resource assigned to the
process is one line worker. The events assigned to the process are mount and
bolt.
❏ Flow Routing Functions in Product Synchronization
Perform product synchronization in Oracle Flow Manufacturing using flow
routings. Flow routings support both processes and sequence of events. In
addition, you can use flow routings to define the network of processes
including feeder lines, rework loops, and primary and alternate processes
required to produce an item.

Setup Steps
You can also use flow routings and the routing network to calculate the total
product cycle time—the longest time path on the production line (including
feeder lines) in making the product.
❏ Planning Percentage Functions in Product Synchronization
You can assign planning percentages to each of the operations including primary
and alternate operations, and rework loops, to use in the calculation of required
material and resources to balance a production line.
Line Scheduling Setup Steps

The primary objective of Line Scheduling is to synchronize production with
customer demand. This objective is achieved through the Line Scheduling
Workbench. To schedule your production, you must first setup the scheduling rules
you will use to prioritize your demand for scheduling purposes
❏ Scheduling Rules Setup
If you are creating a custom rule, this value is user-defined. The following rules
are provided in the system:
■ Mixed Model—mixed model by order request date
■ Level Daily Rate—level daily rate by order request date
■ Request Date—order request date with no leveling
■ Schedule Date—order schedule date with no leveling
■ Promise Date—order promise date with no leveling
■ Production Sequence Forward—order schedule date, order production date
sequence in ascending order with no level loading
■ Production Sequence Reverse —order schedule date, order production date
sequence in descending order with no level loading
The primary objective of setting up production execution is to meet daily
production requirements. This objective is achieved through the setup of Work in
Process Parameters. You can complete assemblies using the Work Order-less
Completions window without having to create a job or repetitive schedule.
Additionally, if you require quality collection plans for work order-less completions.

Setup Steps
Work in Process
Set up parameters in the following tabbed regions of the Work in Process
Parameters window:
❏ Discrete
■ Default Discrete Class: Flow
■ Default Lot Number Type: Based On Inventory Rules
■ Respond To Sales Order Changes: Always
❏ Move Transactions
■ Require Scrap Account: No
■ Allow Creation Of New Operations: Yes
■ Allow Moves Over Move Shop Floor Status: Yes
❏ Backflush Defaults
■ Supply Subinventory: user defined
■ Supply Locator: user defined
■ Lot Selection Method: Expiration Date
■ Lot Verification: Exceptions Only
❏ Other
■ Component ATP Rule: Standard
■ Default Over Completion Tolerance%: n/a

An item that is pulled through the kanban system, rather than pushed by the
planner, is called a kanban item. The kanban location for a kanban item is the
designated location where that item is stored, and where replenishment is
delivered. For every kanban item, there is a pull sequence- a series of kanban
locations that models the actual replenishment network on the shop floor or
external suppliers, specifying the sequence to follow to obtain the kanban item.

Setup Steps
❏ Replenishment Chain Setup

The objective of setting up the kanban replenishment chain is to execute the
flow of the materials through the line:
■ Pull Sequence
■ Sourcing Rules
■ Assignment Sets
❏ Purchasing Blanket PO, ASL, Sourcing Rules and Quotation
You may enter the supplier and supplier site on the pull sequence. This
information is moved to the requisition through the Requisition Import process.
If you do not enter the supplier and supplier site information on a pull
sequence, and a replenishment signal is generated,—the resulting requisition
can pull the source information from a valid source document.

Setup Steps

3
Line Design and Balancing Procedures
This chapter describes the steps to design Flow manufacturing lines including:
Defining Flow Manufacturing Standard Processes on page 3-4
Defining Flow Manufacturing Standard Events on page 3-5
Defining Flow Manufacturing Standard Line Operations on page 3-7
Flow Manufacturing Line Balance on page 3-8
Creating a Flow Routing on page 3-9
Creating a Routing Network on page 3-14
Calculating Operation Times on page 3-15
Operation Times Calculations on page 3-16
Calculating Total Product Cycle Time on page 3-18
Calculating Operation Yields on page 3-19
Operation Yields Calculations on page 3-20
Line Design and Balancing Procedures 3-1

Product Synchronization is the process of defining your product's process flow. This
is done through the Flow routing where you are able to define processes, events and
operations for your flow line. You can then define the process network, add process
yield information, and calculate operation times, yields and total product cycle
time.
Standard processes and standard operations must be created before adding them to
your flow routing. They are created either on the Graphical Line Designer
Workbench, or in the Standard Processes or Standard Operations windows. See:
Creating the Graphical Network on page 4-29
To create product synchronization for standard items:

1. Navigate to the Flow Routing window, and create a Flow routing for an item.
To reduce data entry, you can copy the product family Flow routing to the
product level Flow routings. You can then modify as needed. Processes and line
operations that are copied from the family to the member will retain any
references to corresponding standard processes or line operations.

2. Assign the processes and events that you have defined.
Note: Processes should either be copied or referenced from the

standard processes. Events can be flow routing specific and do not
have to be copied or referenced.
3. Assign resources to non-standard events.
Note: To edit the resources for a standard event, deselect the

referenced check box.
4. Optionally, enter Process Yields.

5. Create a routing network. See:Creating a Routing Network on page 3-14
6. Calculate operation yields.
7. Calculate operation times.
8. Calculate total cycle time (TPCT).
9. Optionally, create a forecast, master demand schedule, and / or master
production schedule with demands for the items.
Note: This step is not part of the product synchronization

procedure and can be performed at any time before generating the
mixed model map.
To create product synchronization for product family items

1. Navigate to the Flow Routing window.
2. Optionally, create a flow routing for the product family item. Assign the
processes and events that you have defined.

standard processes while events can be flow routing specific and do
not have to be copied or referenced.
3. Assign resources to the non-standard events.

Defining Flow Manufacturing Standard Processes

standard processes. Events can be flow routing specific and do not
have to be copied or referenced.
4. Optionally, enter Operation Yields.

5. Calculate Operation Yields.
6. Calculate Operation Times.
7. Calculate total cycle time (TPCT).
8. Create a flow routing for the members of the product family. You can copy the
family routing to the members, then edit as needed. Recalculate Yields
Operation Times, TPCT.
9. Optionally, create a forecast, master demand schedule, and/or master
production schedule with demands for the members of the product family.
Note: This step is not part of the product synchronization

procedure and can be performed at any time before generating the
mixed model map.
Defining Flow Manufacturing Standard Processes

Standard Processes can be created and used only with Oracle Flow Manufacturing.
Processes are generic activities that often comprise of multiple events which are
performed in a specific sequence.
Note: Processes and standard processes can also be created on the

Graphical Line Designer Workbench. See: Creating the Graphical
Network on page 4-29
Prerequisites
To define flow manufacturing processes, you must first define a line in Oracle Work
in Process.
To define a Standard Process for a flow manufacturing line

1. Navigate to the Standard Processes window.

Defining Flow Manufacturing Standard Events
2. Enter the line identifier, sequence number, code and description.

3. Select a department.
4. Optionally, enter a display sequence and minimum transfer quantity.

Standard Events can be created and used only with Oracle Flow Manufacturing.
Events and standard events can only be created and used with Oracle Bills of
Material. Events and Standard Events can also be created on the Graphical Line
Designer Workbench. See: Creating the Graphical Network on page 4-29
Note: When using Oracle Flow Manufacturing, the Operation

Sequence on the Bill of Materials refers to the Event Sequence.
Prerequisites
To define Flow manufacturing line operations, you must first define a line in Oracle
Work in Process.Defining Production Lines, Oracle Work in Process User’s Guide.
To define a Standard Event for a flow manufacturing line

1. Navigate to the Standard Events window.

2. Enter the code and description.

3. Choose the Event Resources button to define resources.
When defining events, you must choose whether a resource is scheduled or not
scheduled. In Flow, a non-scheduled resource is a resource that is used in
parallel to a scheduled resource. Un-scheduled resources are included in the
total time for the resource type (labor or machine), but is not included in the
total elapsed time for the process. Scheduled resources are included in both.
Therefore, in the case of parallel processes, the activity with the longest resource
time should be scheduled because the system elapsed time calculation should
always consider the longest resource time.
See Also
Creating a Routing Network on page 3-14
Calculating Operation Times on page 3-15

Defining Flow Manufacturing Standard Line Operations
Defining Flow Manufacturing Standard Line Operations

Standard operations for flow manufacturing allows you to create line operations for
a regular manufacturing line as well as a flow manufacturing line. In Oracle Flow
Manufacturing, Operations are used to group events into balanced work groups.
They are generally defined and assigned after viewing the Mixed Model Map
although they can be entered at any time.
Note: Operations and standard operations can also be created on

the Graphical Line Designer Workbench. See: Creating the
Graphical Network on page 4-29
Note: When using Flow Manufacturing, the Operation Sequence

on the BOM refers to the Event sequence.
To define a Standard Line Operation for a flow manufacturing line

1. Navigate to the Line Operations window.
2. Enter the line identifier, sequence numbers, code and description.

3. Select a department and optionally choose the remaining options.

Flow Manufacturing Line Balance
Flow Manufacturing Line Balance

To balance a Flow manufacturing line
1. Generate a mixed model map for a line, product family, or forecast. You can also
assign a boost percentage, number of days, and number of hours per day for the
line.
The Mixed Model Map Workbench displays the line takt time, process takt
times, and weighted average times. See: Overview of the Mixed Model Map
Workbench on page 5-2
2. Create line operations for the current line.
See: Creating the Graphical Network on page 4-29
3. Assign line operations to the product level routings.
Attention:
Attention: You can copy or reference all of the line operations for
the current line into the routing to reduce data entry effort.
4. Regroup events on each product level routing into line operations to

approximate takt time.
You can do this by assigning the line operation in the Parent Line Op field of the
event.
5. Create a routing network for operations.
6. Optionally, add yields to operations.
7. Recalculate yields, operation time and total cycle time, using operations instead
of processes.
Regenerate the mixed model map by line operation to review and confirm that
the line is balanced. The mixed model map will also show the resource
(machine/labor) and IPK requirements. See: Overview of the Mixed Model
Map Workbench on page 5-2

Creating a Flow Routing

To create a product synchronization you can design a flow routing including events,
processes, and line operations.
Attention: You cannot create Flow routings for planning or

pick-to-order items.
Prerequisites
❏ You must define at least one department before you can create a routing.
❏ You must define a line.
❏ BOM Allowed must be set to Yes for the item you are creating a routing for.
Note: You can create a routing manually, copy an existing routing,

or reference a common routing. See: Copying Bills and Routings
and Referencing Common Bills and Routings
To create a Flow routing

1. Navigate to the Routing window.
2. Select the item for which you are creating a flow routing.
Note: You can create a flow routing for a product family item.
Attention: For ATO Items, the ATO Model Flow Routing will be
used for line balancing, and will be used to create the configured
routings during auto-create config. Therefore, define a routing for
the model that contains all possible events, processes and
operations for all possible options in your model. Then assign the
model routing as a common routing for all option classes.
3. You can assign an existing routing, copy a routing, or create a new one.
■ To assign a common routing, choose Assign Common Routing from the
Tools menu and select an item to copy.

■ To copy an existing flow routing, choose Copy Routing From in the Tools
menu and select an item to copy.
■ To create a new routing, select the Events, Processes, or Line Operations tab
to define the elements of your flow routing.
4. If you are creating an alternate flow routing, enter an alternate. For a primary
flow routing, do not enter an alternate. See: Primary and Alternate Routings
Note: To create a standard (non-flow) routing for the same item,

you must first switch to the Bills of Material responsibility.
5. Enter the line for which you are creating the flow routing.
6. If you are updating an existing flow routing, enter the routing revision and the
effective date.
Note: Items can have flow and non-flow routings. To define

non-flow revisions, you must switch to the Bills of Material
Responsibility.
7. Optionally, enter a total cycle time for the flow routing.

The total cycle time can be manually input now or can be calculated by the
application after you have defined processes and events.
8. If you would like this item to be considered in the capable to promise capacity
check, select the Capable to Promise button.
Note: Capable to promise describes an available to promise

calculation that considers both available material and capacity of
manufacturing and distribution resources. You are able to define
one and only one CTP routing for each item.
9. Select a display option to display All, Current, or Future and Current

operations effective as of the revision date you specify.
10. There are three ways to set up events, processes, and operations:

■ Choose the Process tab and enter the first process sequence and code.
Choose the Events button and enter all events for that process. Close and
repeat for all processes. When you are ready to balance your line, choose
the operations tab to enter operation sequences and codes. Then assign
events to the operations through either the event tab or the routing network
designer.
Note: The sequence number determines the order in which the

processes are displayed in the Mixed Model Map Workbench.
■ Choose the Process tab, and enter in all process sequences and codes.
Optionally, choose the Operations tab, and enter all operation sequences
and codes. Choose the Events tab, and enter in each event in sequence,
assigning each to a process, and optionally operation.
■ Choose the Process tab, and enter in the desired processes. Optionally,
choose the Operations tab and enter the desired operations. Choose Events,
and enter the desired events. Use the Routing Network Designer to assign
events to a process, and optionally, to line operations.
Attention: In Oracle Flow Manufacturing, the operation sequence

on the BOM refers to the event sequence on the routing where the
part is used.
Note: The operation sequence and code must be unique for each
flow routing.
11. If you are using non-standard events or editing standard events, choose the
Event Resources button from the Events tab and define resource values. For an
event, you can also define a department, parent process, and parent line
operation.
Note: Processes and line operations must already be assigned to

the routing before you assign them to events. See: Three Ways to
Setup Events, Processes, and Operations.

12. Enter an effective date range.
13. For operations in ATO model and option class flow routings only, indicate
whether the event is option dependent. An event is option dependent when the
event is dependent on the choice of an optional component. The default is
enabled. A configured routing will contain all selected components and their
related events, all mandatory components and their related events, and all
events which are not assigned to a specific component.
Note: All processes and operations will always appear on the

configured routing, regardless of whether or not any events
assigned to them are included.
Note: You can attach Operation Method Sheets (OMS) to routing

events. This will enable you to create custom OMS for ATO items.
14. Choose the WIP tab to indicate whether to backflush components on shop floor
moves at this operation. A backflush transaction automatically pulls operation
pull components from inventory. Work in Process also pulls all Operation pull
components at non-backflush operations preceding this operation using the
previous completed backflush operation. The default is Enabled.
15. Choose the Operation Times tab to define or view operation times and yields.
16. To view rolled-up operation times, select Calculate Operation Times from the
Tools menu. Optionally, enter user defined times. Either can be used in Mixed
Model Map Workbench calculations.
17. Switch to the Operation Times tabbed region and optionally enter operation
yield values for processes and/or line operations.
Note: Operation yield values are required to perform calculation

of cumulative and reverse cumulative operation yields.
18. Create a routing network.
19. Once the routing network is created, calculate cumulative yield, reverse
cumulative yield, and net planning percent, by selecting Calculate Operation
Yields from the Tools menu. Choose Update Events to add these yields and

calculations to events. This is required if you want kanban planning to consider

process yields when calculating kanban sizes.
Note: You can also manually insert these values.
20. To calculate Total Product Cycle Time, choose Total Cycle Time from the tools
menu.
21. To enter completion subinventory and locator information, view a common
flow routing, or enable the routing for use in the Mixed Model Map Workbench
choose the Routing Details button to open the Routing Details window.
Note: If this item is a member of a product family, it will be

specified in the Product Family field of the Routing Details
window. This field is read-only.
Note: For an item to be eligable for display and use in the Mixed
Model Map Workbench for a line, you must have a routing enabled
for Mixed Model Map. You can only select one routing per item to
be included in a mixed model map.
22. While in the Routing Details window, optionally, enter a priority. Lowest
priority routing will be used for backflushes and during auto-create config on
ATO items.
23. Save your work.

Creating a Routing Network
Creating a Routing Network

In defining product synchronization you must specify the network of processes
through which the item is routed. This includes specifying alternate processes,
planning percent, rework loops, rework percentage, and feeder lines. The Routing
Network Designer is a graphical tool that allows users to define a product routing
network as a visual network of operations and flows.
Prerequisites
❏ You must have defined events and either processes or line-operations.
❏ If you are using a copied routing, you must first save the routing before you can
see and edit the routing network.
To create a flow routing network:

1. From the Routing window, choose Routing Network.
2. Choose to view either processes or line-operations by selecting the appropriate
tab.
When the Routing Network Designer window appears, all of the processes or
line operations are listed in the left canvas and graphically represented on the
right.
Attention:You cannot mix processes and line operations in the

same window.
3. Choose Connector at the top of the screen to create a link between any two
processes/line operations.
4. Then select a process or line operation and drag to the process or line operation
you are linking.
A window displays, enter the connection type and the percentage of material
from is moving from the source.
Note: If you drag a connection and drop it on a part of the canvas

or where there are no processes/line operations, the entire
drag-and-drop sequence is cancelled.

Calculating Operation Times
Note: The total outgoing primary and alternate path percentages

must be less than or equal to 100%. If you try to make a path in
which the total outgoing percentage to greater than 100%, you will
get an error.
5. You can associate an event with a process/line operation by dragging the event
to a process or line-operation directly above the events.
If you have not already associated events with processes or line operations, the
events are listed on the bottom left of the window.
If you have already associated events to processes and/or line operations, you
can drill down into a process or line operation to view the events composing the
process/line operation. Events are moved from process to process by dragging
and dropping.
When you drag and drop events around the Routing Network Designer tree,
the times on the process and Line Operation nodes change dynamically.
6. You can access node information through two buttons located on the right of
the tool bar.
Description: allows you to view the description on the nodes.
Times: allows you to view the machine, labor and elapsed times on the nodes of
the tree. You can toggle between User Times or Machine Calculated Times
views.
Note: Any event can be associated with one and only one process
or line operation.
7. Save your work.

See: Creating the Graphical Network on page 4-29
Calculating Operation Times

You can calculate machine time, labor time, and elapsed time for your processes,
line operations, and events defined in your flow routing. You can also enter your
own machine times, labor times and elapsed times in the Flow Routing window.

Operation Times Calculations
Prerequisites
❏ You must first define any events, processes and line operations to be included in
your flow routing.
To calculate operation times

2. Place your cursor in the Total Cycle Time field in the header.
3. Select Calculate Operation times from the Tools menu. Choose to calculate
either process times or operation times.
Note: In the Flow Routing window the unit of measure for all
times is hours.
Note: You must re-perform the operation times and total product
cycle time calculations any time you make a change to events,
processes or operations.
Note: You can also enter your own machine times, labor times,
and elapsed times in the Flow Routing window. To do so,
manually enter this information in the User Machine Time, User
Labor Time, and User Elapsed Time fields. You determine when
creating a mixed model map, whether the calculations are based on
rolled-up or user entered times.

The operation times calculations are based on resources in the Flow Routing which
have the resource unit of measurement (UOM) in the UOM class associated with the
BOM profile option, BOM: HOUR UOM.
Calculated Labor Time

Calculated labor time per event is the sum of both scheduled and unscheduled
labor resource usage rates for the event. Calculated Labor Time per process or
operation is the sum of the labor times for all the events underneath each process or

operation. If you entered events by lot, it will temporarily convert the number to an
item basis for the purposes of this calculation.
Note: For ATO model routings: The program goes to the

multi-level BOM for the model, and searches for the planning
percentage on items that are assigned to specific routing events. It
then multiplies the calculated labor time for this event by the
planning percent to get a weighted value for the event time. If an
event is NOT assigned to any part on the multi-level BOM,
planning percent is assumed to be 100%
This will work only if you define a routing for the ATO model, and
than use it as a common routing for all the option classes
underneath it.
Each Option on the routing must belong to a unique event in order
for operation calculations to be successful.
Calculated Machine Time

Calculated Machine Time is the same as Calculated Labor time, only it uses the
scheduled and unscheduled machine resources for each event.
Calculated Elapsed Time

Calculated Elapsed Time for each event is the sum of the scheduled Labor and
Machine usage rates for each event. Elapsed time per process or operation is the
sum of the elapsed times for all the events underneath each process or operation. If
you entered events by lot, it will temporarily assumes the time entered is per item
for the purposes of this calculation.
Times for ATO model routings are adjusted based on the planning percent of the
item assigned to an event, as described in calculated labor times.

Calculating Total Product Cycle Time
Calculating Total Product Cycle Time

You can calculate the total product cycle time (TPCT) for your line. TPCT is the sum
of all elapsed event times along the longest path on your Flow Line.
Prerequisites
❏ You must first define the events, processes and/or line operations to be
included in your flow routing.
❏ You must first create a routing network for either processes or operations.
❏ You must first calculate operation times
To calculate Total Product Cycle Time

3. Select Calculate Total Cycle Time from the Tools menu. Choose to calculate
either process times or operation times.
Total Product Cycle time is always calculated using the rolled-up (system calculated)
elapsed times, even if you entered manual elapsed times. You can manually enter a Total
Cycle Time as well.
You must re-perform the operation times and total product cycle time calculations any
time you make a change to events, processes or operations.
Once the routing network and the Total Cycle Time for a routing is finalized for
each item on your flow line, return to the organization item master and update
the fixed lead time to equal your total cycle time. The Takt time (which is
displayed on the MMM) for the line should be entered in the variable lead time
Note: In the Flow Routing window, the unit of measure for all
times is hours.

Calculating Operation Yields
Calculating Operation Yields

The system will calculate the cumulative yield, reverse cumulative yield and net
planning percent for each process and line operation. This information is used in
Mixed Model Map Workbench calculations and kanban planning.
Prerequisites
❏ Optionally, enter a value for yield at some or all processes or line operations.
❏ You must define a routing network for either the processes or the line
operations.
To calculate operation yields

3. Select Calculate Operation Yields from the Special menu.
4. Select process or operation. Choose update events to translate yields and net
planning percent to events.
Attention: You must update events (manually or by choosing to

update events when you perform the calculations) if you want
kanban planning to consider yields when sizing kanbans.
Attention: If you have yields in your line, you must either

calculate or manually enter operation yields for each process/line
operation for the mixed model map results to be accurate

Operation Yields Calculations

The system will calculate the cumulative yield, reverse cumulative yield and net
planning percent for each process and line operation. This information is used in
Mixed Model Map Workbench calculations and kanban planning. Please see the
diagram below for an illustration of the set-up used in the example calculations.
In the above example, the primary path is operation 10 through 50. The numbers in
parenthesis are the yields for the operation number above it, as entered by the user.
The percentages on the network paths represent the network percent assigned to
each path via the routing network designer. Blank paths assume 100% network
percentages. (The incoming network percentage for the first operation and the
outgoing network percentage for the last operation is always 100%.
)
Attention: Any alternate path must skip at least one operation (or
process) on the main line in order for the yield and planning
percent calculations to work properly.

Net Planning Percent

The system calculates the net planning percent by using the following formula.
N c = S (Pp * I c) + Sr (Io*Wo)
Where:
N = Net Planning Percent, in decimal format
S = sum over all paths
P = Planning Percent = (Pp * I c) (system calculated - not displayed)
Note: Planning percent for the first operation is always 100%.
I = Incoming Network Percent, in decimal format (From Routing Network)
Note: Incoming network percent for the first operation is always

100%.
p = previous operation
c = current operation
Sr = Sum over all rework loops within which is this operation
W = Rework percent (from the routing network)
o = Operation originating the rework
In other words, the system calculates the net planning percent by taking the sum
over all primary and alternate paths of the product of the network percentages
along that path, then adds a rework calculation if the operation is within the rework
loop. The planning percent and incoming network percent for the first operation on
the primary path is always 1. The planning percent for the Feeder line is always the
same as the operation to which they feed.
The rework calculation is equal to the planning percent of the rework’s originating
operation, times the rework percent coming from that operation (in this example,
OP50 is the originating operation for the rework, and it’s planning percent is 100%,
and the rework loop is 5%. Therefore the rework calc is 100%*5% = 5%. This value is
added to all operations in the loop (30, 40 and 50)

The number of paths are determined by working backwards along primary and
alternate paths from the end of the line (so in the example, operations 30, 40 and 50
each have two paths due to the alternate path.
Attention: If a rework loop returns to an operation that is also fed

by a feeder line, the feeder line will include the rework loop percent
in the Net Planing Percent.
Incoming Network Rework Net Planning

Operation Percent Planning% Calculation + Calculation Percent
10 100 1*1 + 0 1
20 80 1* 0.80 + 0 0.84
25 20 1* 0.20 + 0 0.20
30 100 (1 * 0.80 * 1) + 1 *.05 1.05
40 100 (1 * 0.80 * 1 * 1 + 1 * 0.20 * 1) + 1 *.05 1.05
50 100 (1 * 0.80 * 1 * 1 * 1 + 1 * 0.20 * 1 * 1) + 1 *.05
100 feeder - so it uses 0.80 + 0 0.80
network% from 20
200 feeder - so it uses 0.80 + 0 0.80
network% from 20
Cumulative Yield
The cumulative yield for the first operation along the main line and any feeder lines
is the yield entered by the user. The system calculates the cumulative yield for all
other operations using the following formula:
C c = Y c * S (Cp * Pp * I c / Pc)
Where:
C = Cumulative Yield
Y = Yield (User entered)

S = sum over all paths

P = Planning Percent, in decimal format (P = Net Planning% - Rework Calc)
I = Incoming Network Percent, in decimal format (From Routing Network)
p = previous operation
For example, operation 20 in the example above:
C20 = Y20 * S(C10 * P10 * I20 / P20) = 0.90 * (1 *1 * 0.8 / 0.8) = 0.9
Starting from the front of the line, the results for the example are:
Incoming
Network% Plan%
Yield (from routing (from table Cumulative Yield Cumulative
Operation (User Entered) network) above) Calculation Yield
10 blank 100 1 1 1
20 0.90 80 0.8 0.90 * (1 * 1 * 0.8 / 0.8) 0.90
25 blank 20 0.2 1 * (1 * 1 * 0.2 / 0.2) 1
30 blank 100 0.8 1 * (0.9 * 0.8 * 1 / 0.8) 0.9
40 0.95 100 1 0.95 * ((0.9 * 0.8 * 1 / 1) 0.874
+ (1 * 0.2 * 1 / 1))
50 0.98 100 1 0.98 * (0.874 * 1 * 1 / 1) 0.8565
100 blank 100 1 1 1
200 blank 100 1 1 * (1 * 1 * 1 / 1) 1
Reverse Cumulative Yield

The reverse cumulative yield for the last operation along the main line is the yield
entered by the user. The system calculates the reverse cumulative yield for all other
operations using the following formula:
R c = Y c * S (O c * R n)
Where:
R = Reverse Cumulative Yield
Y = Yield (User entered)

O = Outgoing Network Percent, in decimal format (From Routing Network)
Note: Outgoing network percent for the first operation is 100%.
n = next operation
S is the sum over all outgoing paths
For example, operation 20 in the example above:

R20 = Y20 * S(O 20 * R 30) = 0.90 * (1 * 0.931) = 0.8379
Reverse
Reverse Cumulative Cumulative
Operation Yield Outgoing Network% Yield Calculation Yield
50 0.98 100 0.98
40 0.95 100 0.95 * (1 * 0.98) 0.98
30 blank 100 1 * (1 * 0.931) 0.931
20 0.9 100 0.9 * (1* 0.931) 0.8379
25 blank 100 1 * (1 * 0.931) 0.931
10 blank 80 and 20 1 * ((0.8 * 0.8379) + (0.2 * 0.85652
0.931))
200 blank 100 1 * (1 * 0.838) 0.8379
100 blank 100 1 * (1 * 0.838) 0.8379

4
Graphical Line Designer Workbench
This chapter describes the functionality in the Graphical Line Designer Workbench
including:
■ Overview of the Graphical Line Designer Workbench on page 4-2
■ Navigating on the Graphical Line Designer Workbench on page 4-3
■ Accessing Graphical Line Designer Workbench Windows on page 4-9
■ Adding a New Item Routing on page 4-18
■ Deleting a Routing on page 4-21
■ Copying and Common Flow Routings on page 4-22
■ Copying a Routing to a Different Flow Line on page 4-25
■ Viewing Routing Revisions on page 4-27
■ Using the Routing Details Window on page 4-28
■ Creating the Graphical Network on page 4-29
■ Modifying the Line Operation Tree and Process Tree on page 4-36
■ Modifying Line Operations, Processes, Events, and Connections on page 4-37
■ Creating Routings in the Template Routings View on page 4-41
■ Mass Changes on Item Routings on page 4-43
■ Component Assignments on the Bill of Material on page 4-49
■ Specifying Cost Rollup Resource Information on page 4-52
Graphical Line Designer Workbench 4-1

Overview of the Graphical Line Designer Workbench
Overview of the Graphical Line Designer Workbench

The Graphical Line Designer Workbench offers an integrated user interface for
performing product synchronizations. This workbench enables the automatic
creation of standard processes, standard events, and standard operations by using
defaulted information. The features in the Graphical Line Designer Workbench
include:
■ Ability to drag and drop icons onto a canvas to add processes, events and line
operations to the item routing.
■ Processes, events, and line operations added to a routing are also automatically
added to the line as a standard entity.
■ Routing calculations are automatically performed every time a change is made
to the routing.
■ Information fields for Quality, value added, and process efficiency
■ Ease of use features for drawing size changes, and graphical view of network
planning percentage connections under 100 percent.
See Also
Navigating on the Graphical Line Designer Workbench on page 4-3
Accessing Graphical Line Designer Workbench Windows on page 4-9
Events, Processes, and Line Operations

Events represent the detailed work content of your line. You can assign resources
and times to events.
Processes are generally logical groupings of events that represent what is being done
on the shop floor before going to flow. They can equal the discrete routing opera-
tions (assembly, welding, machining, test, and so forth). They can also be at an even
lower level than that—especially in an assembly environment (assemble fan, add
engine, inspect welds, and so forth). You may want to define processes first to give
you a chance to take a look at the balance of your shop before moving to flow, using
the Mixed Model Map Workbench. It gives you a starting point to divide or group
work to equal takt. You are not required to define processes.
Operations are balanced groupings of events, and represent the workstations on
your flow line. They may be more detailed than processes such as when one process

Navigating on the Graphical Line Designer Workbench
is divided into several operations. Or, operations may be more generic such as when
several processes are grouped into a single operation. This may be the case in a low
volume assembly shop. Operations must be defined in order to be able to scrap
assemblies through work order-less completions, to use the flow workstation, and to
perform feeder line synchronization.

The Graphical Line Designer Workbench is comprised of two panes. The left pane is
the tree hierarchy and the right pane displays the graphical network.
The View By list box allows you to change the way you view data in the tree—your
choices are by Item, Product Family, or Common Routing.
There are two tree tabs located to the left of the tree hierarchy that enable you to
toggle between the Item Routings and Template Routings views on the right pane.
The Item Routings tab displays the routings for all items assigned to the designated
line, while the Templates tab gives access to product family routings that can be

used as templates for copying information into routings. The right pane contains
the data that is associated with the selected item on the tree. When an item is
selected four tabs at the bottom of the window provide access to windows
displaying Line Operation network, Line Operation Tree, Process network, and
Process Tree.
Resizing the Detail Pane

You can change the size of the detail pane—enabling you have a larger working
canvas area when creating and modifying the graphical network.
To resize the Graphical Line Designer Workbench window:

❏ Select the button between the navigation tree, and the detail pan, to maximize
the window.
When you maximize the window size in this method, the navigation tree is not
displayed. This button enables you to toggle between the full screen and
divided pane sizes.

❏ You can also resize the detail pane by resizing the entire workbench. Select the
resize icon
This method maximizes the window size, and also displays the navigation tree.
This icon enables you to toggle between the full screen and smaller pane sizes.
Workbench Toolbars
In the right pane canvas, there are two toolbars containing icons used for creating
and modifying your graphical network. One toolbar displays when you are in the
Line Operation or Process windows.
This toolbar contains icons for:

■ Connector: Enables you to create links between entities on the canvas

■ Pointer: Allows you to move existing entities on the canvas

■ Process: Enables you to add a new process to the routing
■ Line Operation: Enables you to add a new line operation to the routing
■ Event: Enables you to add a new event to the routing
The other toolbar displays when you are in the Operation Tree or Process Tree
windows.
It contains three icons that allow you to change the display view of the tree
including:
■ Vertical Style: The tree is displayed in an up-and-down format by routing, line,
line operation code, and description.
■ Organizational Chart Style: The tree is displayed in a hierarchical box format. The
routing is at the top level, the lines, line operation codes, and descriptions are
graphically displayed below the routing.
■ Interleaved Style: The tree is displayed in an indented hierarchical box format.
The routing is at the top level and displayed on the left of the pane—the line,
line operation codes, descriptions are graphically displayed to the right of the
routing.
■ Showtime: Toggles the view of the event, line operation and process times when
viewing the data in a tree format.
This toolbar also contains two pull down menu boxes. One box allows you to
choose views on the pane by either current, future and current or all events on the
routing.
The Times box has two selections, Calculated Times and User Times. This enables
you to choose whether to view the operation time that is calculated by the system or
entered in manually

Tools Menu and Pop-up Menus

The Graphical Line Designer Workbench enables you to access other manufacturing
functionality. These options are available, depending upon the currently active
window and other conditions, in the Tools menu and pop-up menus.
The Tools Menu

Standard Events: Accesses the Standard Events window. It displays all standard
events for a particular line. Defining Flow Manufacturing Standard Events on
page 3-5
Standard Processes: Accesses the Standard Processes window. It displays all standard
processes for a particular line. See:Defining Flow Manufacturing Standard Processes
on page 3-4
Standard Line Operation: Accesses the Standard Line Operations window. It displays
all standard line operations for a particular line. See: Defining Flow Manufacturing
Standard Line Operations on page 3-7
Mixed Model Map: Accesses the Mixed Model Map Workbench enabling you to
generate a mixed model map. See: Overview of the Mixed Model Map Workbench
on page 5-2
Resource Where Used: Accesses the Resource WhereUsed window in Oracle Bills of
Material for viewing the operation and routings that use a particular resource. See:
Viewing a Resource Usage, Oracle Bills of Material User’s Guide.
Routing Revisions: Accesses the Routing Revisions window to view the changes for a
particular routing. See: Viewing Routing Revisions on page 4-27
Switch to Primary: Allows you to switch the selected alternate with the primary
routing.
Items: Accesses the Master Item window in Oracle Inventory where you can define
and update items and the attributes associated with them . See: Defining Items,
Oracle Inventory User’s Guide.
Product Family Members: accesses the Product Family window, enabling you to
group products that have a similarity in resource usage, design, and manufacturing
processes. See: Assigning Product Family Members, Oracle Bills of Material User’s
Guide.
Bills of Material: Accesses the Bills of Material window that contains information on
the parent item, components, attachments, and descriptive elements. See: Creating a
Bill of Material, Oracle Bills of Material User’s Guide.

Indented Bills: Accesses the Indented Bill of Material window in Oracle Bills of
Material where you can view an indented (multilevel, exploded) manufacturing or
engineering bill of material. See: Viewing an Indented Bill of Material, Oracle Bills of
Material User’s Guide
Lines: Accesses the Production Lines window in Oracle Work in Process. See:
Defining Production Lines, Oracle Work in Process User’s Guide
Departments: Accesses the Departments window in Oracle Bills of Material. See:
Defining a Department, Oracle Bills of Material User’s Guide
Item Selection List: Accesses the Apply Changes window for creating mass changes,
edits, and deletions on multiple flow lines. See: Mass Changes on Item Routings on
page 4-43
Set Resource Cost Rollup: Accesses the Set Resource Cost Rollup window used to
specify if an event is included in the cost rollup. See: Specifying Cost Rollup
Resource Information on page 4-52
Pop-up Menus
You can access windows and functions in the pop-up menus by right-clicking on an
icon in the right pane, or a node in the tree hierarchy.
The following choices are available, depending upon the currently active window
and other conditions, by right-clicking on an operation, process, event, or
connection icon in the right pane:
■ Cut: Allows you to remove an operation, process, event, or any connections to it
from the item routing.
■ Paste: Allows you to restore an operation, process, event, or connection you
have just cut from the item routing.
■ Delete: Allows you to permanently remove the operation, process, event, and
any connections to it from the item routing.
■ Properties: Accesses the Operation, Process or Event window. For example, if
you select an event, the Event window opens.
■ Standard: Accesses the Standard Line Operations, Standard Processes or
Standard Events window—depending on which entity you have selected. For
example, if you select a process, the Standard Processes window opens.
The choices available in the pop-up menu in the tree hierarchy include the
applicable Tools menu, Workbench menu options, and these additional menu
options in the tree hierarchy:

Accessing Graphical Line Designer Workbench Windows
■ New: Accesses the Add Item Routing window enabling you to create new
routings. See: Adding a New Item Routing on page 4-18
■ Routing Details: Accesses the Routing Details window enabling you to view
specifics or to add information to a routing. See: Using the Routing Details
Window on page 4-28
■ Copy/Common Routing To: Accesses the Copy Routing window used to copy that
items’s routing to other items—or create routings that are common to it. See:
Copying and Common Flow Routings on page 4-22
■ Copy Routings To: Accesses the Copy Routings window enabling you to copy a
routing to a different flow line. See: Copying a Routing to a Different Flow Line
on page 4-25
■ Component Assignments: Accesses the Update Component window where you
can associate the components on the bill of material with the routing events
where they are consumed. See: Component Assignments on the Bill of Material
on page 4-49
■ Delete: Accesses the Delete Routing window to delete a routing from your
navigation tree. See: Deleting a Routing on page 4-21

◗◗ To access windows for creating product synchronizations:
1. Select the Graphical Line Designer from the Flow menu.
The Select window displays.
2. In the Line field, select the assembly line you want to view on the workbench.

3. In the Time Unit of Measure field, select the unit of measure you are using for
routing calculations.
Your choices are hour, minute, or second.
4. In the Precision field, select a value for the number of decimal places you want
displayed in routing calculations.
Your choices are 1, 2, 3, 4. For example, if you enter 2—two decimal places
display.
5. Select a Calculate Option for calculating the Current Total Cycle Time. This
value displays on the workbench. Your choices are:
■ Automatic—Current Total Cycle Time is automatically calculated every
time there is a change or update.
■ Deferred—Current Total Cycle Time calculation is only initiated manually.
when you select Calculate s on the workbench.
6. Choose OK.
The Graphical Line Designer displays.
In the initial view the Item Routing tree tab is selected and the tree hierarchy is
collapsed. The two tree tabs located to the left of the tree hierarchy allow you to
toggle between the Item Routings and Template Routings views on the right
pane.

The Item Routings tab displays the routings for all items assigned to the line
designated. In the initial view the right pane is blank, when you select an item,
the graphical network displays.
■ The View By list box is used to select the way you want to view data in the
tree.
■ The Current Total Cycle Time field displays for this item. It is calculated
automatically every time you change tabs, add entities on the routing, or
change items. See: Calculating Total Product Cycle Time on page 3-18
■ The Line Rate value defaults from the line definition.
In the Item Routing node, you can search for routings using the Search Results
node, or view all the routings in the All Routings node.

7. In the View By list box, select to view data in the tree by Item, Product Family,
or Common Routing.
If you choose product family and the items are assigned to a product family, the
product family displays in between the line and item.

8. If you want to find a specific record, or range of records, select the Search
Results node and right-click with your mouse to display the pull-down menu.
9. Select Search to display the Search Items window.
10. Enter search criteria; you can search by item, category, planner, or any
combination of these values.

11. Choose OK to display the results of your query under the Search Results node.

12. To display information in the right pane, select a node detail on the tree.
The graphical network displays a view of the line operation network in the first
window tab, Line Operation.
You can add, change, delete, or move the icons in the graphical network. See:
13. Select the Line Operation Tree tab.
14. Left-click with your mouse to select a node detail on the tree hierarchy.
In the right pane the top level of the routing for this item displays.

15. Expand the items on the routing to display the operations in the routing.
You can change the tree format to one of three styles. See: Workbench Toolbars
on page 4-5 The icons in the tree will change to match those on the toolbar for
the three entities. The last node at the bottom of the tree is named Unassigned
Events. This a place holder for all the events that are on the routing but are not
assigned to any line operation. For example, an event may be unassigned
because you defined processes first, and have not assigned the events to the
operations.
You can add, change, delete, or move the icons in the tree. See: Modifying the
Line Operation Tree and Process Tree on page 4-36
The code and description are listed for each line operation and event.
The toolbar enables you to view the line operations and events on the routing
by current, future and current, or all events. You can also see the times
associated with each line operation and event.

16. Select the Process tab.

The graphical network displays a view of the process.
17. Select the Process Tree tab.
18. Select a node detail on the tree hierarchy, and left-click with your mouse.
19. Expand the items on this routing to display the processes in the routing.
You can change the tree format to one of three styles. See: Workbench Toolbars
on page 4-5 The icons in the tree will change to match those on the toolbar for
the three entities.
The last node at the bottom of the tree is named Unassigned Events. This a
place holder for all the events that are on the routing but are not assigned to any

Adding a New Item Routing
process. For example, an event may be unassigned because you defined the
operations first, and have not assigned the events to the processes.
You can add, change, delete, or move the icons in the tree. See: Modifying the
Line Operation Tree and Process Tree on page 4-36
The code and description are listed for each process and event.
The toolbar has an option that enables you to see the times associated with each
process and event.

The Add Item Routing window enables you to create new routings on the Graphical
Line Designer Workbench. You have three options in creating routings. You can
create a routing as an entirely new routing, copy it from another item or a template,
or assign a common routing as a reference for the new routing.

◗◗ To add a new item routing:

1. Navigate to the Graphical Line Designer Workbench.
2. Select the top node on the tree hierarchy, Item Routings, and right-click with
your mouse.
The pop-up menu displays.
3. Choose New.
The Add Item Routing window displays.
4. To create a new routing, select an item from the list of values in the Item field,
and enter any appropriate information in the Alternate, Capable to Promise,
Revision, and Date fields.
See: Creating a Routing, Oracle Bills of Material User’s Guide.
5. To create a routing by copying one from another item or a template, choose
Copy From Item/Template in the Routing Source region.
Your current Organization information displays.

In the Item field, select the routing to be used as a template from the list of
values.See: Creating Routings in the Template Routings View on page 4-41
Enter the any appropriate information in the Alternate, Revision, Engineering
Routing, and Date fields. See: Creating a Routing, Oracle Bills of Material User’s
Guide.
Select a Copy Option, your choices are:
■ Current: operations effective on the revision date
■ Future and Current: includes current and all future operations
6. To create a routing from a common routing, choose Assign Common Routing.
Any two items that are of the same bill type can share common bills and
routings. See: Referencing Common Bills and Routings, Oracle Bills of Material
User’s Guide.
7. Select the routing you want to use from the list of values.
8. Optionally, you can choose Related Routings to view a list of the other routings
that have been defined for this item on all the lines in this organization.
9. Choose OK to close the Related Routings window.

10. Choose OK to close the Add Item Routing window.
The new routing appears at the bottom of the routings list on the tree hierarchy,
and it is highlighted. If this is a new routing, the right pane canvas is blank. If
the routing was created from a template or a common routing, the right pane
displays the inherited routing information.

Deleting a Routing
11. Save your work.
Deleting a Routing
You have the option to delete a routing from the navigation tree by selecting a
default delete group, or creating a new one. All operations are deleted when a
routing is deleted. Any links to attachments are also severed.
To delete an item routing:

2. Select the top node on the tree hierarchy, Item Routings, and right-click with
your mouse.
3. Choose Delete from the pop-up menu to display the Delete Routing window.
4. In the Name field, select the name of a Delete Group. The description displays
for this group.

Copying and Common Flow Routings
5. You also have the option to create a new Delete Group. Choose New Group to
display fields for creating a new delete group.
6. Enter a value in the New Group Name and Description fields.

7. Choose OK to save the New Delete Group Name.
8. Choose OK to save your work.
9. Navigate to the Deletion Groups window to delete the routing. See: Deleting
Items, Bills, Routings, Components, and Operations, Oracle Bills of Material
User’s Guide

You can select an item on the navigation tree, and then copy that items’s routing to
other items—or create routings that are common to it.
Note: If an item already has a primary routing, the copy common

transaction is not created.
You can also copy a routing to another flow line. When you select items and copy
the routing to another flow line—all relevant standard operations, processes, and
events are duplicated.See: Copying a Routing to a Different Flow Line on page 4-25
◗◗ To copy or common a flow routing:

1. Select the node detail for the item you want to copy to other items, then
right-click with your mouse.
The pop-up menu displays.

2. Select Copy/Common Routing To.

The Copy Routing window displays. The Source region displays the Item name
and description.
3. In the Option region, choose either Copy or Common.

■ Use Copy for copying this item’s routing to one or more items. Select
Current, or Future and Current to indicate the effective date. The system
uses the effective date on the Routings window for the operation code.
■ Use Common to create one or more routings that are commoned to this
routing.
4. In the multi-row Item region, select the items and, if applicable, alternate
designators, where the Source item is copied.
5. To add multiple items, choose Retrieve.
Add Item Retrieve window displays. This window restricts your search for
items according to your specifications.

6. Select your search criteria.
You can search by any combination of values including item, product family,
category, planner, or alternate designator.
If this routing is for a Configure to Order model you can search for items by
option class. Choose Common in the Option region, and enable the Retrieve
Only Option Classes box. The system retrieves items for all option classes under
the model and criteria specified.
7. Choose OK to display the list on the Copy routings window.
8. Choose Copy.
You will receive a confirmation message when the transaction is completed. You
can view the copied routing for the item on the hierarchical tree and right pane
of the Graphical Line Designer Workbench.

Copying a Routing to a Different Flow Line

You can copy a routing to a different flow line, enabling you to maintain multiple
design models. All standard operations, processes, and events on the selected
routing are copied to the line. When you perform the copy function:
■ Both flow lines must be within the same inventory organization
■ You have the option to duplicate the bill of material
■ Only current and future versions of the routing and bill of material are copied
■ When copying a referenced routing, the original routing referenced is copied
◗◗ To copy a routing to another flow line:

2. Select the All Routings node, and right-click with your mouse to display the
pop-up menu.

3. Select Copy Routings To.

The Copy Routings window displays.
4. In the Destination region, select the line where the data will be copied.
5. In the Alternate field, enter the alternate destination designator.
Flow routings names must be unique; the alternate designator is the new
identifier for this copied routing. Either select an existing alternate designator
from the list of values, or enter a new alternate name.
6. Optionally, you can copy the bill of material information by checking the Copy
BOM check box.
7. In the Source Criteria region, specify the assembly to be copied in the Assembly
field. Or select a range of criteria for copying.
You can specify a range by assembly name, total product cycle time, alternate
designator, or line operation and process.
8. Choose Copy
The selected routing information is copied to the destination line with the given
alternate designator and includes standard line operations, processes, events,
and event resources.

Viewing Routing Revisions
Viewing Routing Revisions

The Routing Revisions enables you to view all the revisions and changes for a
particular routing.
◗◗ To view the revisions for a specific routing:

1. Select a routing detail on the tree hierarchy
2. From the Tools menu or the pop-up menu, select Routing Revisions.
The Routing Revisions window displays. This window lists all the revisions and
information for a specific routing. See: Creating a Routing Revision, Oracle Bills of
Material User’s Guide.

Using the Routing Details Window
Changing from an Alternate to a Primary Routing

◗◗. To change your routing from an alternate routing to a primary routing:
1. Select a routing on the tree hierarchy that is an alternate routing.
The tree hierarchy displays alternate routings by designating the alternate name
in parenthesis on the tree.
2. From the Tools menu or the pop-up menu, select Switch to Primary.
The Switch to Primary window appears with the alternate designation
displaying. You can choose this routing, or select another routing from the list
of values.
3. Save your work.

See: Switching Between Primary and Alternate Routings, Oracle Bills of Material
User’s Guide.
Using the Routing Details Window

You can access the Routing Details window for a particular routing to view specifics
or to modify information.
◗◗ To view or modify routing details:

2. Left-click with your mouse to select a node detail on the tree.
The graphical network displays a view of the line operation in the first window
tab, Line Operation.
3. Choose Detail.

Creating the Graphical Network
The Routing Details window displays.
You can change several of the fields on this window including: Date, Capable to
Promise, Mixed Model Map, Priority, Subinventory, Locator, Comment, and
Display. See: Creating a Routing Revision, Oracle Bills of Material User’s Guide.
In the tabbed region, you can also modify Yield, User Labor, or User Machine
Times for any line operation, process, or event.
4. Save your work.
The routing calculations are performed automatically.

Product Synchronization is the process of defining your product's process flow. This
is done through the flow routing where you are able to define processes, events and
operations for your flow line. The Graphical Line Designer Workbench provides
icons in the toolbar that you can drag and drop onto the right pane canvas to create
the product synchronization. This graphical interface allows you to create, delete,

cut, and paste line operations, processes, events—and their connections. You can
also add new item routings, see: Adding a New Item Routing on page 4-18
To add a new line operation on the Graphical Line Designer Workbench:

1. Select the Line Operation tab to display this window in the detail pane.
2. Select the Operation icon from the toolbar.
This icon is only available in the Line Operation window of the workbench.
3. Left-click with your mouse on the right pane, in the section of the canvas where
you want to locate this line operation.
The Line Operation window displays.
4. Enter the Display Sequence and Code values.
You have the option of entering a new code in the Code field, this creates a new
standard line operation code which is added to the routing. Or you can select a
code from the list of values, which adds the existing standard code to the
routing.
5. Subinventory and Locator values default from the referenced standard

operation. You have the option to enter values if there is no referenced standard
operation.

6. Enter values in the Routing Specific Details region.

If the Referenced check box is checked, the information displayed for the
Descriptions field is referenced from the standard line operation. To edit,
deselect the referenced check box.
Information displays for Yield, Cumulative Yield, User Machine Time, Elapsed
User Time, Net Planning Percent, Cumulative Yield, Reverse Cumulative Yield,
and Process Efficiency values for machine and labor
See:Mixed Model Map Calculations on page C-10, and Operation Yields
Calculations on page 3-20
You can access the Line Operation window through the pop up menu if you
want to modify this data for a standard line operation.
7. Choose OK to close the window and perform routing calculations.
The new line operation displays on the canvas.
8. Save your work.
◗◗ To add a new process on the Graphical Line Designer Workbench:

1. Select the Process tab to display this window in the right pane.
2. Select the Process icon from the toolbar.
This icon is only available in the Process window of the workbench.
3. Left-click with your mouse on the right pane, in the section of the canvas where
you want to locate this process.
The Process window displays.

The information in the top region of the window is defaulted from where you
positioned the icon on the workbench. You can change Display Sequence and
Description information.
4. Enter values in the Routing Specific Details region.
Description field is referenced from the standard process. To edit, deselect the
For information on Net Planning Percent, Cumulative Yield, and Reverse
Cumulative Yield, see Operation Yields Calculations on page 3-20
You can access the Standard Processes window through the pop up menu if you
want to modify this data for a standard process.
The new process displays on the canvas.
6. Save your work.
◗◗ To add a new event on the Graphical Line Designer Workbench:

1. Select either the Line Operation or Process tab to display one of these windows
in the right pane.
2. Select the Event icon from the toolbar.

This icon is only available in the Line Operation and Process windows of the
workbench.
3. Left-click with your mouse on an existing line operation or process in the right
pane.
The Event window displays.
4. Enter values in the Routing Specific Details region including Yield, Effectivity
Date, and Disable Date.
Description field is referenced from the standard event. To edit, deselect the
For information on Net Planning Percent, Cumulative Yield, and Reverse
Cumulative Yield, see Operation Yields Calculations on page 3-20
You can access the Standard Events window through the pop up menu if you
want to modify this data for a standard process.
5. Use the Option Dependent box to indicate if this event is dependent on the
choice of an optional component.
6. Enable the Critical to Quality box if this is a quality related task.

7. Enable the Value Added box if this event adds value to the Process. Resource
Efficiency calculations for the process or line operation consider this setting.
8. The Include Resource in Cost Rollup box is used to specify if the event is
included in the cost rollup. This flag can be updated here, or from the Set
Resource Cost Rollup window. See: Specifying Cost Rollup Resource
Information on page 4-52
9. Optionally, indicate whether the resource is available 24 hours a day. You
cannot assign shifts to a resource that is available 24 hours a day.
The new process displays on the canvas.
11. Save your work.
Defining a Network Connection

The Network Connection window is used when adding or modifying a connection
on the Graphical Line Designer. This window is accessed though the pop up menu
on the right pane.
Note: Network planning percentage connections under 100

percent display on the detail pane of the graphical network.
To add a network connection on the Graphical Line Designer

Workbench:
1. Navigate either to the Line Operation network or Process network window on
the right pane of the Line Designer.
2. Select the Connections icon from the toolbar.
This icon is only available in the Line Operation and Process windows of the
workbench.
3. Left-click and hold with your mouse on the right pane, on the process or line
operations where you want to start this connection—and drag the line to the
process or line operation you want to it to join.
The Network Connection window displays. In the Operation From and To
fields, the operation codes that you connected on the canvas automatically
display.

4. You can use the defaulted values in the Transition Type and Planning Percent
fields, or enter other values.
Transition type values are primary alternate, and rework.
The planning percent is the percentage of product that follows this network
path. If the planning percent for the network connection is less than 100 percent,
the value displays on the graphical network detail pane.
The new connection displays on the canvas.
6. Save your work.

Modifying the Line Operation Tree and Process Tree
Modifying the Line Operation Tree and Process Tree

The Line Operation Tree and Process Tree windows display your product
synchronizations for your routing network in a tree hierarchy format. The Graphical
Line Designer Workbench enables you to modify the routing network tree—you can
create, delete, cut, and paste line operations, processes, and events.
◗◗ To modify components on the Line Operation Tree and Process Tree:

1. Select either the Line Operation Tree or Process Tree tab to display the
hierarchical view of the routing network.
2. Left-click with your mouse to select a node detail on the tree hierarchy.
3. Expand the items on the routing to display the operations or processes in the
routing.
The code and description are listed for each line operation and event.
You can change the tree format to one of three styles. The toolbar has an option
that enables you to see the times associated with each line operation and event.
See: Workbench Toolbars on page 4-5
The last node at the bottom of the tree is named Unassigned Events. This a
place holder for all the events that are on the Routing but are not assigned to
any line operation or process. For example, an event may be unassigned
because you defined processes first, and have not assigned the events to the
operations.
4. Select a detail on the tree and right-click to display the pop up menu.
The pop up menu displays, depending on the conditions, several options: Cut,
Paste, Delete, Properties, and Standard.
5. Select an event and drag it to another line operation.
Routing calculations are automatically performed.
6. Save your work.

Modifying Line Operations, Processes, Events, and Connections

The Line Operation window is used when adding or modifying a line operation on
the Graphical Line Designer. It contains routing specific details. This window is
accessed though the pop up menu on the right pane.
To modify a line operation on the Graphical Line Designer Workbench:

1. Navigate to the Line Operation Tree or Line Operation network window on the
right pane of the Line Designer.
2. Select the line operation you want to modify on the right pane canvas.
If you are adding a new line operation, see: Creating the Graphical Network on
page 4-29
3. Right-click on the operation icon in the right pane to display the pop up menu.
See: Tools Menu and Pop-up Menus on page 4-7
4. Select Properties.
The Line Operation window displays. The information is defaulted from the
icon on the workbench. You can change Display Sequence, Yield, User Machine
Time, User Labor Time information. To change the description, uncheck the
Referenced box. See: Creating the Graphical Network on page 4-29.

6. Save your work.

The Process window is used when adding or modifying a process on the Graphical
Line Designer. It contains routing specific details. This window is accessed though
the pop up menu on the right pane.
◗◗ To modify a process on the Graphical Line Designer Workbench:

1. Navigate to the Process Tree or Process network window on the right pane of
the Line Designer.
2. Select the process you want to modify on the right pane canvas.
If you are adding a new process, see: Creating the Graphical Network on
page 4-29
3. Right-click on the process icon in the right pane to display the pop up menu.
The Process window displays. The information is defaulted from the icon on the
workbench. You can change Display Sequence, Yield, User Machine Time, User
Labor Time information. To change the description, uncheck the Referenced
box. See: Creating the Graphical Network on page 4-29
6. Save your work.

The Event window is used when adding or creating an event on the Graphical Line
Designer. It contains routing specific details. This window is accessed though the
pop up menu on the right pane.
To modify an event on the Graphical Line Designer Workbench:

1. Navigate either to the Line Operation Tree or Process Tree window on the right
pane of the Line Designer.
2. Select the event you want to modify on the right pane canvas.
If you are adding a new event, see: Creating the Graphical Network on
page 4-29
3. Right-click on the event in the right pane to display the pop up menu.
The Event window displays. The information is defaulted from the icon on the
workbench. You can change Display Sequence, Effectivity Date, and Disable
Date information. If you uncheck the Referenced box, you can change

description and resource information. See: Creating the Graphical Network on

page 4-29
6. Save your work.
The Network Connection window is used when adding or creating a connection on
the Graphical Line Designer. This window is accessed though the pop up menu on
the right pane.
◗◗ To modify a network connection on the Graphical Line Designer

Workbench:
1. Navigate either to the Line Operation network or Process network window on
the right pane of the Line Designer.
2. Select the connection you want to modify on the right pane canvas.
3. Right-click on the icon in the right pane to display the pop up menu. See: Tools
Menu and Pop-up Menus on page 4-7

Creating Routings in the Template Routings View
The Network Connection window displays and you can change the values, see:
Defining a Network Connection on page 4-34
Note: Network planning percentage connections under 100

percent display on the detail pane of the graphical network.
5. Save your work.

The Template Routings tree tab provides access to Product Family Routings that can
be used as templates for copying elements to an item routing you are creating. You
can define a routing for a product family the same way as performed in the Item
Routings view of the workbench, and can perform all the same functions as in the
routings region.
Using product family routings as templates:

1. Choose the Template Routings tree tab.

2. Select Template Routings node detail on the tree, and left-click with your
mouse.
The Template Routings tab displays the routings for all Product Families
assigned to the line designated. In the initial view the right pane is blank.
3. Select New from the popup menu.
Or you can create a new product family routing. In the Add Item Routing
window, use the option to create an entirely new routing. See: Adding a New
Item Routing on page 4-18
After you select a routing, a blank Line Operation window displays in the right
pane. This blank window is the canvas used as a template.
4. Use the toolbar to add icons to create a routing network. See: Creating the
Graphical Network on page 4-29
5. Save your work.
This routing is now available to use when creating a new routing, see: Adding a
New Item Routing on page 4-18

Mass Changes on Item Routings

You can simultaneously make changes, edits, and deletions to multiple flow
routings. Work performed in the graphical pane can be updated for all items on the
line, or in the product family. To enable this functionality, check the Mass Change
check box on the graphical pane of the Graphical Line Designer Workbench. Mass
change functionality is only available in the Line Operation and Process windows of
the Graphical Line Designer Workbench:
❏ In the View by Item mode, you can mass change all item routings on that
production line.
❏ In the View by Product Family mode or the Template Routing tree tab view, you
can mass change routings that belong to the same product family.
❏ In the View by Common Routing mode or the Template Routing tree tab view,
you can mass change routings that belong to the same common routing.
Changes are still created by selecting an icon or menu item, and making the changes
on the related line operation, process, event, or connection property window.
However, in the mass change mode, you can also:
■ Populate changes to a range of other item routings after you save the
transaction
■ Update operation information for user machine time, user labor time, and yield
■ Revise outgoing network connections from the node for planning percentages
and transition type allocations
◗◗ To make mass changes to item routings:

2. Check the Mass Change check box on the graphical pane.
3. Select the line operation, process, event, or connection icon, and make the
changes in the related window. See: Creating the Graphical Network on
page 4-29
4. Choose OK on the related line operation, process, event, or connection window
to save the transaction and display the Apply Changes window.
When first viewed in a session, this window does not display data. The applied
values from your query default for the subsequent operation changes.
You can also access this window from the Tools menu by selecting Item
Selection List.

5. Enter the specific items you want to change, and any applicable alternate
designators.
6. You can also search for item routings by choosing Retrieve to display the
Retrieve Routings window.
7. Select search criteria in Retrieve Routings window.

You can search by item or range of items, product family, category, planner, and
alternate designator.
8. Check the Retrieve Only Applicable Items check box to display only eligible
item routings.
Eligible item routings are in context to the changes:
■ For event changes or deletions, routings with line operations or processes
referencing that specific event. When adding the event, routings with line
operations or processes that do not already have that event.
■ For line operation and process changes, routings with those specific line
operations and processes.
If you do not select this check box, and all search criteria fields are
empty—when you choose Find all items routings display.
Note: Even though you can display all routings, updates occur
only on applicable routings.
9. Choose Find to display your search on the Apply Changes window.

Uncheck the items you do not want included in the mass update.
10. Choose Apply to create the mass update transaction.
You can view the routing changes on the graphical pane of the Graphical Line
Designer Workbench.
◗◗ To update operation user time and yield information:

1. Navigate to the Graphical Line Designer Workbench, and check the Mass
Change check box.
2. Select an operation, and right-click with your mouse to display the pop-up
menu.

3. Select Mass Change to display the Operations window.
4. In the Change By region, enter applicable changes for the Value fields.

You can enter a new value in the Value field for User Machine Time, User Labor
Time, and Yield.
Alternately, for the User Machine Time and User Labor Time columns, you can
enter either a value or percentage to add or subtract from the current value. For
example:
If the Current Value for User Machine Time on operation LP50 is 1.26
And you enter .4 in the +/- Value field
The system adds .4 to 1.26, to equal 1.66
When you apply your change, the system updates the User Machine Time on
operation LP50 to 1.66—in all instances where it occurs on the selection list of
item routings.
5. Choose OK to display the Apply Changes window.
6. Select your edit list criteria.
You can choose Retrieve to display the Retrieve Routings window for your
search criteria; and use the Retrieve Only Applicable Items check box for
eligible items. Choose Find to display your search on the Apply Changes
window, and uncheck any items you do not want included in the mass update.
7. Choose Apply to update your changes.
Eligible items are those with values in the applicable fields for the selected
operation.
◗◗ To update outgoing network connections:

1. Navigate to the Graphical Line Designer Workbench, and check the Mass
Change check box.
2. Select a node on the graphical pane, and right-click with your mouse to display
the pop-up menu.

3. Select Outgoing Network Connections to display the Network Connections

window.
4. Enter changes in the Planning Percent fields.

Network planning percentage connections under 100 percent display on the
detail pane of the graphical network. The total planning percent must equal 100
in order to update item routings.
5. Choose OK to display the Apply Changes window.
6. Select your edit list criteria.
You can choose Retrieve to display the Retrieve Routings window for your
search criteria; and use the Retrieve Only Applicable Items check box for
eligible items. Choose Find to display your search on the Apply Changes
window, and uncheck any items you do not want included in the mass update.
7. Choose Apply to update your changes.
Eligible item routings are those with same the geometry match including:
■ The same specified network connection
■ The same outgoing network connections defined for the To Operation
■ Transition type and destination must match the current item routing

Component Assignments on the Bill of Material
■ If you check the Match Planning Percentage check box, the planning
percents must match and not exceed 100

You can associate the components on the bill of material with the routing events
where the components are consumed. This association links one or more
sub-inventory and locator combinations to line operations—and then automatically
updates the material control portion of the parent bill of material.
These transactions are performed on the Update Components window. This
window is accessed from the Graphical Line Designer Workbench by selecting the
item routing in the hierarchical tree; or the line operation, process, or event in the
graphical pane. A bill of material must exist for the selected routing in order to
display this window.
◗◗ To assign components to a bill of material:

2. Select either an item routing on the hierarchical tree; or a line operation,
process, or event in the graphical pane.
3. Right-click with your mouse to display the pop-up menu, and select
Component Assignments.
The Update Component window displays.
Information defaults on the Components region of the window depending on
your selection. For example, if you access the window from the line operation
or process—the line operation and any associated events display. If you access
the window from the event—the line operation and all instances of this event
display. And if you select the item routing, all lines and events display.

4. You can also use the upper region of the window to enter criteria for a new
query.
■ In the Display Option field, choose the display mode, within the context of
other specified parameters, for the Components region of the window. Your
display choices are:
Assigned—retrieves components assigned to any event for this
specified routing.
Unassigned—retrieves components that are not currently assigned to
any event in this specified routing. This mode enables you to assign
components to the routing.
All—retrieves all components both assigned and unassigned.
■ Optionally select a value, or range of values in the Line Operation field.
■ Optionally select a value in the Event field.

■ Optionally select an item number, or range of components in the

Components field.
5. Choose Find to displays the results of your query. on the Components region.
6. Optionally, you can manually change the Event, Subinventory, and Locator
values for any component listed.
The component attributes are displayed for event, line operation, item
sequence, component name, subinventory location, and locator.
7. Check the Mass Assignments check box if you want update the records in your
query in mass update mode.
Several different mass update transactions are available including:
■ Activates the Mass Assignment Selection check boxes for each component
on the Components region. Select components by checking the Mass
Assignment Selection check boxes in individual rows. This field is disabled
when the Mass Assignments check box is not checked.
■ Choose Select All to activate all the records on the window.
■ Choose Unselect All to deactivate all the records on the window.
8. The Mass Assignments check box also enables the Mass Assignments region on
the window. You can enter values in the Event, Subinventory, and Locator
fields.
9. Check the records in the Components region you want to update.
10. Choose Assign to update the applicable records and fields on the Components
region.
11. Choose OK to update the component assignment to the bill of material for the
item routing selected
All specified components on the window are updated on the item routings’s bill
of material. The Graphical Line Designer Workbench displays again.
If you selected Mass Change on the Graphical Line Designer Workbench—the
Apply Changes window displays. See: Mass Changes on Item Routings on
page 4-43
12. Save your work.
13. Select Bills of Material from the Tools menu to view the update in the Bills of
Material window.

Specifying Cost Rollup Resource Information

The Set Resource Cost Rollup window is used to specify if an event’s resources are
included in the cost rollup. If you include an event in the rollup, the checkbox on
the Event’s window is enabled. See: Creating the Graphical Network on page 4-29
This window provides a method for creating a mass change for events on a
particular item routing.
To set resources for cost rolllup:

2. Select an item routing on the hierarchical tree, and choose Set Resource Cost
Rollup from the Tools menu.
The Set Resource Cost Rollup window displays, showing all the events and line
operations for this routing.
3. Enable the Include box for the event and line operations you want included in
the cost rollup. Use the Exclude box for events you do not want calculated in
the cost rollup.
4. Choose OK.

5. Save your work.
See Also
Rolling Up Supply Chain Costs, Oracle Cost Management User’s Guide


5
This chapter describes the features of the Mixed Model Map Workbench, a
graphical interface used to balance your production lines. Topics include:
■ Overview of the Mixed Model Map Workbench on page 5-2
■ Viewing, Creating, and Updating Plans on page 5-4
■ Viewing Plan Production Line and Line Operation Information on page 5-7
■ Viewing Plan Resource Information on page 5-16
■ Resource Assignment on page 5-21
■ In Process Kanban Assignment on page 5-22
■ Filtering and Sorting Information on page 5-24
Mixed Model Map Workbench 5-1

Overview of the Mixed Model Map Workbench

The Mixed Model Map Workbench is a graphical interface for monitoring line
balancing—the process of defining production lines by including the products
made, operations performed, and resources and materials consumed at each step. It
is used to balance a line against specified demand—and calculate process volume,
machine and labor requirements, TAKT times, and In-Process Kanban (IPK)
requirements. The Mixed Model Map Workbench provides:
■ A tree navigation graphical workbench displaying information at different
detail levels for plans, lines, operations, resources.
■ Detail panes for each node selected on the navigation tree.
■ The ability to analyze and balance lines, or run simulations, considering both
the assigned resources and the In Process Kanbans (IPK) available.
■ Both a line operation and process view enabling the assignment and analysis of
resource demand across multiple production lines.
■ Support for multiple plans for simulation studies.
■ Identification of resource usage and problem operations.
■ The ability to use unscheduled planned orders and sales orders as a type of
demand.
■ An engine using demand as input to calculate the resource/IPK usage as
needed for each resource, at each operation.
■ Display and calculation of resource efficiency and resource total units for a plan.
■ Display of line demand and line capacity in summary view.
■ Update of item variable lead time using line TAKT.
The workbench displays a navigation tree, and a detail pane for each node selected
on the tree. There are two tree tables enabling you to toggle between the Line
Operation and Process regions. Both regions display a line and resource view:
■ The Line Operation region displays operations specific to the line, as derived
and defined during line balancing. This region shows the resulting line
information after mixed model map calculations.
■ The Process region displays the activities performed in defined processes on the
line. This region shows the result of mixed model map runs for all the
processes.

The Navigation tree contains three nodes—when a node is selected the

corresponding detail pane displays:
■ All Plans—All the plans defined in the organization selected.
■ Resource Assignment—The total available units from applicable departments,
and total assigned units to operations for a resource.
■ IPK Assignment—In Process Kanbans assigned, a summary of all the IPK
master assignments.
See Also
Viewing, Creating, and Updating Plans on page 5-4
Viewing Plan Production Line and Line Operation Information on page 5-7
Viewing Plan Resource Information on page 5-16
Resource Assignment on page 5-21
In Process Kanban Assignment on page 5-22
Mixed Model Map Workbench Calculations on page D-2

Viewing, Creating, and Updating Plans

The Plans node displays all the plans in the selected organization. This enables you
to view multiple plans using different line balancing techniques. You can view the
details of a specific plan by selecting the node in the navigation tree, the data
displays in the canvas.
To view or update a plan:

1. Select the All Plans node, and expand the navigation tree to display the plans.
2. Select a plan to display the pane for this plan’s definition.
3. Update the fields you want to change.
4. Choose Calculate or Replan

If you choose Calculate, the mixed model map calculation is performed based
on the parameters specified for this plan. Calculations use assigned values for
resources, IPKs, and the demand values. A confirmation displays if the process
is successful.

If you choose Replan, the current assigned values for recalculation. A

confirmation displays if the process is successful.
5. Save your work.
To create a new plan:

1. Select the All Plans node, and right click to display the Menu.
2. Choose New to display the pane for entering your plan definition.
3. Enter a unique name in the Plan Code field, and optionally any description for
this plan.
4. Optionally, you can select values in the Product Family, a group of products
with similar characteristics, and product Line fields for this plan.
5. In the Demand Type field, select a value representing the source of this demand.
Your choices are:
■ Forecast—an estimate of future demand
■ MDS—master demand schedule, the anticipated forecasted ship schedule
■ MPS—master production schedule, the anticipated forecasted build
schedule
■ Actual Production—demand generated from existing Flow schedules
■ Sales Orders
■ Planned Orders
6. If the value in the Demand Type fields is Forecast, MDS, or MPS, you are
required to select a Demand Name value.
7. The Start and End Date values are derived from the forecasted demand, and can
be changed.
Demand Days for this Demand Type display. Demand days are the number of
working days in between specified demand start and end date.
8. The Hours Per Day field displays the working hours for this line. This value can
be changed.
9. You can enter a Boost Percent value. This specifies an increase percentage of the
demand in the plan.
10. Choose a Calculation Option. This region is used to select how operational cycle
times, resource requests, and IPK values are calculated. Your choices are:

■ No IPK—resource requirements are calculated using the IPK value as zero

on the line operation.
■ Based on one resource—the IPK needed on the line operation is calculated
assuming one resource at each operation.
■ Based on assigned IPK—resources are calculated using the assigned IPK at
the line operation.
■ Based on assigned resource—the IPK needed on the line operation is
calculated using all the assigned resources.
11. The Display Options region is used for selecting viewing options for the
generated mixed model map. Indicate how you want to display time in the
Time Uom field. Your choices are Hour, Minute, or Second.
12. In the View By field, indicate the sort option, on the navigation tree, for this
plan’s process or line operation display. Your choices are Display Sequence,
Operation Code, or Description.
13. The Precision field is the decimal setting for your calculation values. Your
choices are 1,2,3, or 4 decimal places.
14. Choose Calculate to run the mixed model map calculation based on the
parameters specified for this plan.
Calculations are performed based upon assigned values for resources, IPKs,
and the demand values. A confirmation displays if the process is successful.
15. Optionally, choose Replan to use the current assigned values for recalculation.
A confirmation displays if the process is successful.
16. Optionally, choose Update Assignment to copy the assigned resources and IPKs
in this plan to the master resource and IPK assignments. A confirmation
displays if the process is successful.
17. Save your work.
After you create or update information in this window, you can perform three
processes.

Viewing Plan Production Line and Line Operation Information

Production line information is available on the workbench in summary, line detail
and line operation, and graphical views. You can use the summary view to
determine if there is an imbalance in the line, resource overload, or IPK assignment.
You can then view the details of a specific line and line operation.
Line Operation views enable you to access resource and labor information.
The production line views enable you to copy the values that are required in the
Needed fields to the Assigned fields. In the navigation tree, right click to display the
menu, and choose. Select Copy Needed To Assigned.
You can also update item variable lead times by copying the line TAKT time. In the
navigation tree, right click to display the menu, and choose Update Items Variable
Lead Time. This function copies the value of the plan's:
(Line TAKT / Line hours per day) for each line to the corresponding Items'
Variable Lead Time
See Also
Line Summary View on page 5-8
Line Detail - Summary View on page 5-9
Line Detail - Resource/IPK Table View on page 5-11
Line Detail - Graphical View on page 5-12
Line Operation - Detail View on page 5-13
Line Operation - Graphical View on page 5-14
Color Representation on the Mixed Model Map Workbench on page D-5

Line Summary View

The Line Summary pane displays fields for Line name, Hours, Daily Demand, line
TAKT time, Assigned TAKT time, Daily Capacity—and two regions—Resource
Percentage and IPK Percentage. These regions display maximum Over and Under
values for the line.
The Line Hours field can be updated. This is the continuous working hours for the
line.
Line TAKT and Assigned TAKT fields display values so you can compare capacity.
Line TAKT is the rate the line produces one item to fulfill demand. Assigned TAKT
is the time per unit that each operation produces, given the number of resources
assigned.
The Daily Capacity value is a statement of process capability. It is equal to the
Assigned TAKT multiplied by the hours.
Color coding provides a visual display of these comparisons. See: Color
Representation on the Mixed Model Map Workbench on page D-5

In the Resource Percentage region, Over signifies a resource overload. That is, the
resource needed is greater than the resource assigned in the line. Under signifies
that the resource is not sufficiently used.
In the IPK Percentage region, Over means that there is IPK overload. That is, the
IPK needed is greater than the IPK assigned in any of the line operations or
processes. Under signifies that IPK are not sufficiently used.
Detail information for these values and modifications created here is available in
tabbed regions for Summary, IPK Table, and Graph.
Line Detail - Summary View

The Line Detail panes are view only windows. In the Line Detail view, the
Summary tabbed region shows line operation detail information in a table format.
The line name, line hours, and line TAKT display.
The table displays the operation information including Operation name, Operation
TAKT, Operation TAKT as Assigned, Resource Capacity, and Process Efficiency.
Both over-assigned and under-assigned resources display in the Resource Capacity

column. Process Efficiency is a statement of value-added activities. It is equal to the

line operation efficiency multiplied by the demand.
Color coding provides a visual display for comparisons of values needed and
exceeded. See: Color Representation on the Mixed Model Map Workbench on
page D-5
You can filter or sort the data displayed in the table by choosing Filter/Sort. See:
Filtering and Sorting Information on page 5-24
You can view item demand details of the line operation and operation TAKT for the
line by choosing Item Details from the Summary tabbed region. See: Viewing Item
Details for a Line on page 5-16
You can copy the values that are in the required in the Needed fields to the
Assigned fields. In the navigation tree, right click to display the menu, and choose.
Select Copy Needed To Assigned.
navigation tree, right click to display the menu, and choose. Update Items Variable
Lead Time.

Line Detail - Resource/IPK Table View

The Resource/IPK Table tabbed regions contain two table areas—Resources and In
Process Kanbans regions.
The Resources region displays line resource details including fields for Resource,
resource Type, resources Needed, and resources Assigned. You can filter or sort the
data displayed in the table by choosing Filter/Sort. See: Filtering and Sorting
The In Process Kanban regions displays a table showing the line operation, and
values needed and assigned.
The production line views enable you to copy the values that are in the needed
fields to the assigned fields. In the navigation tree, right click to display the menu,
and choose. Select Copy Needed To Assigned.
navigation tree, right click to display the menu, and choose. Update Items Variable
Lead Time.

Line Detail - Graphical View

The Graph tabbed region of the line detail displays a graphical view of the line
resource and IPK values. In the View By field, you can change the graph
information from percentage values or absolute values. There is a choice of three
views including:
■ Percentage Needed: the percentage difference between Assigned and Needed
values—divided by the Needed value. Over-assigned and under-assigned
resources display on this view.
■ Percentage Assigned: the percentage difference between Assigned and Needed
values—divided by the Assigned value. Over-assigned and under-assigned
■ Absolute Value: Needed and Assigned values display for comparison.
You can modify the display by filtering or sorting the data by choosing Filter/Sort.
See: Filtering and Sorting Information on page 5-24
You can enlarge the graph by double-clicking on the graph. Double click again to
return to the original view. You can also use the cursor to drag over a region to

enlarge a section of the graph. Use your cursor to rollover text details on the graph
to display tooltip information.
page D-5
Line Operation - Detail View

Line Operation Detail views display specific data for the operation node selected.
The Detail tabbed region displays fields for this line operation for Operation TAKT,
Line TAKT, IPK Needed and IPK Assigned.
There are two regions—Labor Resources and Machine Resources region. Both
regions display fields for Resource name, Usage, Needed, and Assigned.
These fields enable you to compare and assign resource capacity values. Color
coding provides a visual display for comparisons of values needed and exceeded.
See: Color Representation on the Mixed Model Map Workbench on page D-5

You can view item demand details of the line operation and operation TAKT for the
line operation choosing Item Details from the Summary tabbed region. See: Viewing
Item Details for a Line on page 5-16
Values can be changed in the Assigned fields and recalculated for a line operation.
Enter the value you want to change, and choose Recalculate. Resources are
calculated and new values display in the usage and needed fields.
Line Operation - Graphical View

The Graph tabbed region of the line operation detail displays a graphical view of
labor resources and machine resources.

In the View By field, you can change the graph information from percentage values
or absolute values. There is a choice of three views including:
You can enlarge the graph display by double-clicking on the graph. Double click
again to return to the original view. You can also use the cursor to drag over a
region to enlarge a section of the graph. Use your cursor to rollover text details on
the graph to display tooltip information.
page D-5

Viewing Plan Resource Information
Viewing Item Details for a Line

The Item Details window display line operation and operation TAKT details for a
specific line. This is a view only window that displays fields for Product, Process
volume, Machine Time, labor time, and Elapsed Time. The Weighted Time values
also display for the time fields.
This window is accessed from the Line Detail view, the Summary tabbed
region—and the Line Operation Detail views by choosing Item Details.

You can view resources needed and assigned for a particular plan—and filter and
sort the displayed information. Resources are displayed in summary and individual
resource detail views.
Resources Summary Views

The Resource Summary views are a view only panes displaying Summary and
Graph regions. Updates can be made on the detail views.
The Summary tabbed region has two regions—Labor Resources and Machine
Resources region. Both regions display fields for Resource name, Needed, Assigned,
and Relocation Needed.

The Relocation Needed field signifies if resources are being allocated sufficiently.
For example, some line operations have extra resources while others need resources.
The values in this field are:
■ Yes—there are extra resources assigned to this line operation, while other
operations have less assigned resources than needed.
■ No—there are no extra resources assigned to this line operation, and no other
operations need this resource.
■ Null—resources needed is greater than resources assigned
These fields enable you to compare resource capacity values. Color coding provides
a visual display for comparisons of values needed and exceeded.See: Color
Representation on the Mixed Model Map Workbench on page D-5
You can modify the display by filtering or sorting the data by choosing Filter/Sort.
See: Filtering and Sorting Information on page 5-24

The Graph tabbed region displays Labor Resources and Machine Resources regions.
Color coding provides a visual display for comparison. See: Color Representation
on the Mixed Model Map Workbench on page D-5

Resource Detail Views

The Resource Detail view shows the resource and IPK needed and assigned in the
line operation across line operations.You can filter or sort the data displayed by
choosing Filter/Sort. See: Filtering and Sorting Information on page 5-24
The resource Assigned can be modified and recalculated. Choose Recalculate to

update resource and IPK values.
The Graph Resource view displays resource details in a graphical view. In the
Absolute Value view, the graph displays the resource and IPK needed and assigned
in the line operation—across line operations. You can filter or sort the data
displayed by choosing Filter/Sort. See: Filtering and Sorting Information on
page 5-24

exceeded. See:Color Representation on the Mixed Model Map Workbench on
page D-5

Resource Assignment
Resource Assignment
The expanded Resource Assignment node enables you to view all your
resources—and display the details for the line, line operation, department, and
assigned values. This pane displays a detail of each line the resource is assigned to,
a total Assigned value. There is Summary region on this window displaying the
department, units, assigned, and totals.
You can update the Assigned field value, and choose Refresh to update the resource
values.

In Process Kanban Assignment

The IPK Assignment pane displays a summary of all the IPK master assignments
for your lines. It displays the IPK assignment for the line and line operation
combination. This data is updated when you choose Update Assignment for a plan,
or when you change values in the IPK Assignment field on this pane.
In Process Kanbans are designated as a work in process holding area for work in
between operations. If the operation time for one operation is shorter in length than
the next operation—the IPK is where the item is designated until the next operation
is available. The outputs are used by the next operation to keep the line flowing. For
example:
■ A Line with 2 working hours, consists of 2 continuous operations—Operation1
and Operation2
■ Operation1 and Operation2 use one resource each—R1 and R2
■ R1 completes an operation every 30 minutes, while R2 completes an operation
every 15 minutes

In order for the line to produce items every 15 minutes, and fulfill 8 demands, IPK
is needed for Operation1 because it takes more time than Operation2.
■ R1 in Operation1 only produces 4 items in 2 working hours
■ R2 needs 8 unfinished items from R1 to produce 8 final items
Therefore, extra items—or IPK—are needed at the end of R1 in Operation 1, so R2 in
Operation 2 can keep producing at its capacity level. IPK can be fulfilled by using
extra line operation resources at the operation.
In Process Kanban Calculation

IPKs are calculated as follows:
(elapsed weighted time - line takt time) * hours/day * time conversion factor
divided by elapsed weighted time * line takt time
The Calculation Options setting in the Plan detail pane is used to select an
operational cycle time setting for the number of resources assigned to the operation.
See Also
Viewing, Creating, and Updating Plans on page 5-4

Filtering and Sorting Information

You have the option to filter or sort table information in the Line Detail, Resource,
and Resource Detail views. This enables you to use sort criteria and ordering
information, or filter criteria to limit your display of records. You can filter and sort
on the Summary, Resource IPK, and Graph tabbed regions.
To filter or sort line detail records:

1. On the Line Detail pane of the selected line, choose Filter/Sort.
The Filter/Sort Criteria window displays.
2. In the Sort Criteria region, choose ordering options for line operation details. In
the Order By field, your choices are Operation, or Operation TAKT.
3. In the Order field, choose the order of display for records—Ascending or
Descending.
4. In the filter Criteria region, you have the option to enter values for filtering your
records. You can enter a value, or range of values, in the Operation TAKT and
Resource Overcapacity fields.
5. You can select an IPK Status value. Your choices are either Over or Under
6. Choose OK to filter and sort your records. The results display on the Line Detail
views.

To filter or sort resource and resource detail records:

1. On the Resource or Resource Detail pane of the selected resource, choose
Filter/Sort.
The Filter/Sort Criteria window displays.
2. In the Sort Criteria region, choose ordering options for line operation details. In
the Order By field, your choices are Resource or Overcapacity.
3. In the Order field, choose the order of display for records—Ascending or
Descending.
4. In the filter Criteria region, you have the option to enter a value, or range of
values, in the Resource Overcapacity field.
5. Choose OK to filter and sort your records. The results display on the Resource
and Resource Detail views.


6
Flow Sequencing
This chapter describes Flow sequencing, the process of determining when items are
built on the production line to create Flow schedules. The following topics are
included:
■ Overview of Flow Sequencing on page 6-2
■ Setting Up Flow Sequencing on page 6-4
■ Viewing and Defining Sequencing Attributes on page 6-8
■ Viewing Sequencing Rules on page 6-10
■ Defining Sequencing Rules and Constraints on page 6-13
■ Assigning Production Lines and Rules on page 6-19
■ Creating Sequencing Tasks on page 6-22
■ Resequencing Tasks on page 6-34
■ Viewing Sequencing Tasks on page 6-34
■ Sequencing Task Details and Results on page 6-37
Flow Sequencing 6-1

Overview of Flow Sequencing

Sequencing is the process of determining the order assembly items are built on a
production line, in a time horizon. Flow manufacturing environments comprise a
mixture of different assembly items, or mixed models, built on the same production
line. The sequence assembly items are built determines the efficiency of the line, and
the efficiency determines the productivity of the manufacturing organization. Flow
Sequencing is a module for considering your demands and determining a sequence
for building assembly items. You use attributes, constraints, and group them into
rules for assigned production lines.
In sequencing tasks, constraints are used to decide the best sequence of production.
Depending on the production mix—constraints are a combination of many factors
including resources, components, and physical dimensions. The Flow Sequencing
concurrent program takes the sequencing task as input, and creates Flow schedules
to meet production demands. Flow sequencing process begins with the initial data
setup. This includes setting up attributes and constraints into rules, and assigning to
production lines. After the setup, the process consists of two tasks:
❏ Specifying parameters including:
■ Date horizon, schedule group, and source of data
■ Production lines
■ Demand
■ Viewing and adjusting demand
❏ Submitting the sequencing task

Flow Manufacturing Sequencing is setup, tasks created, and submitted in the Flow
Manufacturing Sequencing and Execution pages. Attributes, constraints, rules, and
production lines are set up in the Setup tabbed region. Tasks are created in the
Sequencing Tasks tabbed region, and later submitted when your adjustments are
finalized.You first select an organization in order to navigate to the other pages. The
Home page enables you to:
■ View up to the last ten sequencing tasks generated. These are displayed in a
table displaying showing the task Name, Phase, Status, Submission Date, and
the Production Line assigned, and Organization. See: Viewing Sequencing Tasks
on page 6-34
■ Navigate to the Task Summary detail page. See: Sequencing Task Summary on
page 6-36
■ Create a new task. See: Creating Sequencing Tasks on page 6-22
Flow Sequencing 6-3

Setting Up Flow Sequencing

The Setup tabbed region of the Flow Manufacturing Sequencing and Execution
page is used to set up your attributes, constraints, rules, and assign them to
production lines.
Attributes
Attributes are a characteristic of your demand. For example—on an automobile
production line, you can specify an attribute type as Component, and name it Color.
Attribute types can be one of several classes including entity, property, and date
attribute types.
Entities are their names such as Item or Line Operation—where the name of the
item or line operation is the attribute type.
Property types require data attributes from the source table. For example, the Flow
Schedule Property attribute requires an attribute from the Flow Schedule Property
table—such as ALLOCATED_FLAG or DEMAND_CLASS.
Date types also require data attributes from the source table—the specific date type
needed for the attribute. For example, the Sales Order Due Date attribute requires
an attribute from the Sales Order table—such as PROMISE_DATE or REQUEST_
DATE.
The types of attributes in Flow Sequencing are:
■ Component
■ Flow Schedule Property
■ Item
■ Item Category
■ Item Customized
■ Item Property
■ Line Operation
■ Model
■ Planned Order Customized
■ Planned order Due Date
■ Planned Order Property

■ Product Family
■ Sales Order Customized
■ Sales Order Due Date
■ Sales Order Property
Constraints
A constraint is a restriction enforced on an attribute. For example—on an
automobile production line, you have an attribute specified as Color. A constraint is
created on the Color such as the required transition—first red is manufactured, then
black.
Constraints have priorities attached to them, and the priority is unique within a
rule. The sequencing process always attempts to honor constraints from the lowest
to the highest priority.
Note: It is good practice to define priorities in increments of 10.
A value of zero indicates a hard constraint. If these constraints are broken—or

violated—Flow Sequencing stops.
Note: Constraint types do not apply to every attribute type.
Constraints types are:

■ Required Transition: For the constrained attribute, a certain value must be
immediately followed by another certain value on production line. For
example, on a product assembly line—constraint A must be followed by B;
otherwise it is a violation.
■ Forbidden Transition: For the constrained attribute, a certain value must not be
followed by another certain value. For example, on a product assembly
line—constraint A must not be followed by B; otherwise, it is a violation.
■ Grouping: For the constrained attribute, a certain value is on the production
line as a group of certain size (or multiple of that size).
■ Attribute-level grouping: If an attribute value is not specified, the constraint
applies to every value of the constraint attribute.
Flow Sequencing 6-5

■ Unlimited grouping: The group size is not specified, the constraint is a

different value in one group.
■ Spacing: For the constrained attribute, a certain value must be separated by
other values and a specified distance.
■ Attribute-level spacing: if an attribute value is not specified, the constraint
applies to every value of the constraint attribute. Spacing distance is always
required.
■ Capacity: Within any day, or the whole horizon, the number of occurrences of a
certain attribute value cannot exceed a certain limit. There are three types of
capacity constraints:
■ Daily limit – the limit is defined for each every day.
■ Horizon limit – the limit is defined for the whole sequencing horizon.
■ Component Availability – the limit is from checking ATP of a certain
component. In this case, the attribute can only be component,
■ Ordering: Within the sequencing horizon, the values of one or more attributes
appear in either ascending, or descending, order. For example, constraint Order
price descending, engine power ascending—will first order price in descending
order, and engine power in ascending order.
■ Due Date: All demands must be scheduled before the corresponding due date
(for example, sales order promise date).
■ Conditional Transition: For the constrained attribute, a certain value must be
immediately followed by itself, or another certain value on production line. For
example, constraint A must be followed by itself or B—means that on a
production line—every A must be followed by a A or B assembly; otherwise it
is a violation.

Rules
Rules are a grouping of prioritized constraints defined for the attributes. Rules are
assigned to specific production lines. For example, Rule 1 consists of two prioritized
constraints:
Priority Constraint Attribute Description

10 Required Transition Assembly Item Assembly 1 must be
followed by Assembly 2
20 Group Assembly Item Group assembly 3
On an automobile production line, you have an attribute specified as Color, a

constraint created for the required transition. Then you can create another
constraint for spacing— one of every 4 automobiles is red, the rest are black. Then
group the constraints into a rule, and name it Rule 1.
Production Lines
A rule is a collection of constraints, and associated with one or more production
lines.
For example, on an automobile production line, you have an attribute specified as
Color, a constraint created for the required transition. Then you can create another
constraint for spacing—one of every 4 automobiles is red, the rest are black. Then
group the constraints into a rule, and named Rule 1—and associate it with a specific
production line.
Flow Sequencing 6-7

Viewing and Defining Sequencing Attributes

To view sequencing attributes:
1. In the Flow Manufacturing Sequencing and Execution Home page, select a
value in the Organization field and choose Go.
2. Select the Setup tabbed region.
3. Select Sequencing Attributes to display the Sequencing Attributes page.
4. To view existing attributes, enter values in the Search region to filter your
search, or leave these fields blank to display all defined attributes.
You have the option to enter:
■ Name—a unique identifier for the attribute
■ Type—such as Item, Model, or Product Family. See: Attributes on page 6-4
■ Source—this is a table column field for property type attributes.

5. Choose Go to display the results of your search criteria.
To define sequencing attributes:

1. Choose Create Attribute to display the Create Attribute page.
2. In the Type field, select an attribute type.

See: Attributes on page 6-4
Flow Sequencing 6-9

Viewing Sequencing Rules
3. Enter a unique Name, and optionally a Description for this attribute.

4. If you are creating more than one attribute, choose Create Another Attribute to
define another record.
5. Choose Apply to save your work.
A confirmation page displays when all your records are saved.

To view sequencing rules:
1. In the Flow Manufacturing Sequencing and Execution Home page, select an
organization in the Organization region, and choose Go.
2. Select the Setup tabbed region, and choose Sequencing Rules to display the
Sequencing Rules page.
3. Enter values in the Search region to filter your search, or leave these fields blank
to display all defined sequencing rules.
You have the option to enter Name and Description values.

4. Choose Go to display the results of your search criteria.

This page displays a list of rules according to your search criteria. You can also
view details of a rule, assign lines, and update the rule with new information.
See: Assigning Production Lines and Rules on page 6-19, and Constraints on
page 6-5
Flow Sequencing 6-11

5. Select a rule in the Name field to display the Rule detail page.
This page displays the Constraints attached to the rule, and the assigned
production lines. See: Rules on page 6-7

Defining Sequencing Rules and Constraints

Rules are a grouping of prioritized constraints, the constraints use priorities to
determine the sequence of production.
To define a sequencing rule:

1. Choose Create Rule to display the Create Rule page.
2. Enter a unique value for this rule in the Name field, and optionally a
description of this rule.
3. In the Constraints region, select constraint values from the Select Constraint
type box.
4. Choose Create Constraint to display the Create Constraint page.

5. Enter a value in the Priority field, and select an attribute.

The lower the priority number indicates a high priority. A value of zero
indicates a hard constraint that must not be violated. It is good practice to
define priorities in increments of 10. See: Constraints on page 6-5
6. Choose Continue to display the Constraint Details page.
7. Select a component item number for this constraint.

8. Choose Finish to save your work.

The new constraint displays in the Constraints region of Create Rule page.
9. To modify constraints displayed in this list, select a constraint and choose

Update. The Update Constraint for Rule page displays.
You have the option to modify the Priority and Attribute fields.

Viewing and Updating Production Lines
10. Choose Continue to display the Update Constraint Details page.

11. You have the option to change the item on this page.
12. Choose Finish to save your work. The updated constraint displays in the
Constraints region of Create Rule page.
13. If you want to delete any of the constraints created for this rule, choose Delete
for the selected rule.
14. Choose Apply to save your work

Flow manufacturing environments comprise a mixture of different items built on
the same production line. You consider your demands and determining a build
sequence. Rules are associated and assigned to one or more production lines.
To view production lines:


3. Select Production Lines to display the Production Lines page.

4. You have the option to enter values in the Search region to filter your search.
Enter values in the Name or Description fields. You can also leave these fields
blank to display all defined production lines.
To update production line information:

1. Navigate to the Production Lines page.
2. Search for the record to update.
3. Select the production line and choose Update.
The Update Production Line page displays.
4. In the Line Definition region, you are required to enter values in the Hourly
Rate, Start Time, and Stop Time fields.
Note: These values are defaulted from the Production Lines

window.

5. In the Sequencing Default Values region, you can enter default values for when
running the Sequencing Concurrent program for this line. In the Scheduling
Direction box, you have the option to change the scheduling from Forward or
Backward.
6. The Connect Sequence field is used to connect this sequencing task to a

previous sequencing task. Your choices are Yes or No.
This option enables you to sequence between days within the horizon, and
gives you the option to connect the sequences with existing sequences without
violating constraints.
7. The Combine Schedules field is used to combine similar concurrent demand
into one schedule. Your choices are Yes or No.
8. The Fix Sequence field is used to prevent the resequencing of existing Flow
schedule when new demand is added to the schedules, or a portion of the
schedules are resequenced. Your choices are:
■ None—Indicates all existing schedules are resequenced.

Assigning Production Lines and Rules
■ Time—Existing schedules with a completion time less than or equal to this

value are not resequenced.
■ Quantity—Flow schedules up to the specified quantity are not resequnced.
9. In the Assigned Rules region, you can update rule information for this
production line. If you want to change the default rule, select the rule in the
table, and choose Set as Default. The default symbol displays in the Default
field.
10. To delete a rule assigned to this line, select the rule and choose Delete.
11. To assign another rule to this production line, choose Assign Rule.
The Assign Rule to Production Line page displays. See: Assigning Production
Lines and Rules on page 6-19

Rules are used for calculating the best sequence for schedule creation. You can
assign production lines to specific rules, or assign rules to production lines.
To assign a rules to a production line:

1. Navigate to the Production Lines page, and Search for the record to update.
See: Viewing and Updating Production Lines on page 6-16
2. Select the production line, choose Update. to display the Update Production
Line page.

3. In the Assigned Rules region, choose Assign Rule.

Assign Rule to Production Line page displays.
4. Enter a search string in the Rule Name field and choose Search.
The Search and Select page displays with the results of your search.
5. Select a record. The record displays on the Assign Rule to Production Line page.
6. Choose Apply to assign this rule to your production line.
The rule displays in the Assigned Rules region of the Update Production Line
page.
To assign production lines to a rule:

3. Choose Sequencing Rules.
4. Display the appropriate rules. See: Viewing Sequencing Rules on page 6-10
5. Choose Assign Lines to display the Assign Production Lines to Rule page.
In the Rule region, the name and description of the rule displays.

6. In the Assign Production Lines region, select production lines from the
Available box, and move them to the Assigned box.
You can move all the production lines, remove lines, or remove all the
production lines in the Assigned box.

Creating Sequencing Tasks

The Sequencing Task pages display a chronology of steps, or a train, showing where
you are in the process. The train displays Enter Parameters, Select Lines, Filter
Demands, and Adjust and Submit:
■ The first step is to enter parameters for the sequencing run. You create a name
for the task, and specify the horizon dates, any applicable schedule group, and
data used to create new schedules—or if the task is resequencing existing
schedules.
■ The next step is to select the production lines used in this run.
■ In the Filter Demands step, you specify demand dates. The Filter Demands
page has two regions—the first is for selecting demand date. The Optional
region is used to add additional filter information such as assembly, customer,
and attribute. For example, you may want to consider all sales orders of a
specific due date, and then specify the particular customer and assembly
number. This page is not used if you are resequencing existing schedules.
■ The Adjust and Submit Sequencing page enables you to view the relevant
production lines and sales orders, along with the remaining capacity and
quantity to sequence. You can update information, and delete production line
demand attached to this task. The last step is submitting the task. The
sequencing concurrent request is triggered when a task is submitted and Flow
schedules are generated.
Results of the sequencing run display on the Flow Manufacturing Sequencing and
Execution Home, Task Summary, and Task Detail pages.
Note: Flow schedules are viewable on the Line Scheduling

Workbench.
See Also
Entering Sequencing Task Parameters on page 6-23
Selecting Production Lines for a Task on page 6-24
Filtering Demands for a Sequencing Task on page 6-25
Viewing Results and Submitting a Sequencing Task on page 6-26
Sequencing Concurrent Program on page 6-28
Viewing Sequencing Tasks on page 6-34

Sequencing Task Summary on page 6-36

Sequencing Task Details and Results on page 6-37
Entering Sequencing Task Parameters

The Sequencing Task pages display the train of steps to complete. When you
navigate to the Entering Sequencing Task Parameters page, Enter Parameters is
highlighted. This page is used to specify information needed to create a unique task.
You can also select a previous task’s parameters on the Sequencing Task summary
page, rename the task, and create a new submission. See: Viewing Sequencing Tasks
on page 6-34
To enter sequencing task parameters:

1. Navigate to the Entering Sequencing Task Parameters page.
2. Select a Name for this sequencing task.

This must be a unique value, the default value is User Name and the sequential
number following the last task created.

3. Select values in the Schedule Date To and From fields.

4. Optionally, you can enter a Schedule Group
5. In the Type region, choose whether you are Creating New Schedules, or
Resequencing Existing Schedules.
If you are creating new schedules, select the data used to create new schedules.
Your choices are either Sales Order or Planned Order.
6. Choose Next to display the Select Production Lines page.
Selecting Production Lines for a Task

When you navigate to the Enter Production Lines page, Select Lines is highlighted
in the step train.
To select production lines for a sequencing task:

1. Navigate to the Enter Production Lines page by choosing Next from the Enter
Parameters page.

2. Select lines from the Available box, and move to the Selected box.
You can move all the production lines, remove lines, or remove all the
production lines in the Assigned box.
3. Choose Next to display the Filter Demands page.
Filtering Demands for a Sequencing Task

You specify demands dates for creating Flow schedules, and any other criteria used
for this task. This can include assembly part numbers, customer, and sales order
attributes.
Note: This page is not used if you are resequencing existing

schedules because that information was previously entered.

To filter demands for a sequencing task:

1. Navigate to the Filter Demands page by choosing Next from the Enter
Production Lines page.
2. If you want to display sales order information on the Adjust and Submit
Sequencing Task page, enable the Adjust Detail Demands box.
3. Select dates in the Demand Date From and To fields.
4. In the Optional Filter Criteria region, you can select additional sales order
attributes with a formula operator. The operator values are Equals or Between.
In the Add Criteria region, select the attributes in the Attribute box, and the
operator in the Operator box.
5. Choose Add to display these sales order attributes on this page.
For example, you can select the attribute, Assembly Part Number, and the
operator Between. This enables you to list a range of assembly part numbers in
your filter criteria.
Or you can select the attribute, Customer, and the operator Equals. This enables
you to add a specific Customer’s sales orders.
Viewing Results and Submitting a Sequencing Task

The Adjust and Submit Sequencing page is used to view the remaining capacity and
demand for this sequencing task. If you enabled the Adjust Detail Demands box, on
the Filter Demands page, demand data displays in the Selected Orders.
This page enables you to update task parameter lines, delete production line
demand from this sequencing task, and update sales order demand information.
You can also delete, move, or split the sales orders attached to this task.
To edit sequencing task results:

1. Navigate to the Adjust and Submit Sequencing Task page by choosing Next
from the Select Production Lines or Filter Demands pages.
Note: If you are resequencing existing schedules, the Filter

Demands page is not used, and this page displays after the Select
Production Lines page.

The Production Lines region displays Production Line, Description, Remaining

Capacity, and Quantity to Sequence fields:
■ Remaining capacity is the capacity for the line. The value is calculated from
the existing Flow schedules and the line capacity total.
■ The Quantity to Sequence value is calculated from the filter criteria you
selected.
2. To update line task parameters, select a production line. Then choose Update to
display the Update Line Task Parameters page.
See: Updating Line Task Parameters on page 6-28
3. To delete a production line from this task, select a production line and choose
Delete.

4. In the Select Sales Order region, you have the option to delete, move, update, or
split sales orders that are attached to the task. To remove a sales order from
consideration, select the order number and choose Delete.
5. To move a sales order to another production line, select the order number and
choose Move. See: Moving Demand on page 6-31
6. To update the sales order demand or change the routing, select the order
number and choose Update. See: Updating Demands on page 6-32
7. To divide the demand between multiple Flow schedules and other production
lines, choose Split. See: Splitting Demands on page 6-33
8. To submit this sequencing task to create Flow schedules, choose Submit.
The sequencing engine concurrent request is triggered when a task is
submitted. See: Sequencing Concurrent Program on page 6-28
Sequencing Concurrent Program

The last step is submitting the task. The sequencing engine is a concurrent request.
The request takes all information specified in the sequencing task, and generates
Flow schedules.
The result of the sequencing is a series of Flow schedules—build sequences indicate
the order of production.
Updating Line Task Parameters

After you enter sequencing task information, and view information on the Adjust
and Submit Sequencing Task page—you have the option to change the original
parameters. You can modify the time, rate, default sequencing direction, and
constraints on this page.You can also choose to combine schedules, and to connect
with existing schedules.
To update line task parameters:

1. On the Adjust and Submit Sequencing Task page, in the Production Lines
region, select a line.
2. Choose Update to display the Update Line Task Parameters page.
3. Enter a Start and Stop Time range. These fields are required.
4. Enter the Hourly Rate of this line. This field is required.

5. In the Scheduling Direction box, you have the option to change the scheduling
from Forward or Backward.
6. The Connect Sequence field is used to connect this sequencing task to a
previous sequencing task. Your choices are Yes or No.
This option enables you to sequence between days within the horizon. When
sequencing for a specified horizon, this flag gives you the option to connect the
sequences with existing sequences without violating constraints.
7. The Combine Schedules field is used to combine similar concurrent demand
into one schedule. Your choices are Yes or No.
8. The Fix Sequence field is used to prevent the resequencing of existing Flow
schedule when new demand is added to the schedules, or a portion of the
schedules are resequenced. Your choices are:
■ None—Indicates all existing schedules are resequenced.
■ Quantity—Flow schedules up to the specified quantity are not resequnced.
■ Time—Existing schedules with a completion time less than or equal to this
value are not resequenced.

■ Build Sequence—Flow schedules up to the specified build sequence are not

resequenced.
10. In the Rules and Constraints region, you can use the Copy Constraint from Rule
box to select a rule, and use that rule’s constraints. Choose Copy to copy the
constraints to your current process.
The copied constraint displays in the Constraints region. The Constraints region
displays all constraints in the current sequencing task. You can change
priority—and create, modify, or delete constraints.
11. To change the priority level of the constraint, enter the new priority value in the
Priority field. Choose Apply to save your changes.
12. To create a new constraint for this task, choose Create Constraint to display the
Update Constraint page. See: Defining Sequencing Rules and Constraints on
page 6-13
13. To delete a constraint, select the constraint and choose Delete.

14. To update a constraint listed on this page, choose Update. See: Defining
Sequencing Rules and Constraints on page 6-13
Moving Demand
You may want to move demand to another production line. You can only move
demand to an alternate routing, for a production line selected, when you created the
sequencing task. See: Selecting Production Lines for a Task on page 6-24
To move demands on a sales order:

1. On the Adjust and Submit Sequencing Task page, in the Order region, select an
order.
2. Choose Move to display the Move Demands page.
This page displays the sales order information including fields for Order
Number, Line Number, Assembly number, Assembly Description, and the
Current Line for this demand.
3. In the Move to Production Line box, select the production line where you want
to move this line.
You will return to the Adjust and Submit Sequencing Task page displaying the
updated information.

Updating Demands
Demand is based on the assembly’s primary routing. The Update Demands page
enables you to change either one or both of the values for the quantity to sequence,
and the routing. The alternate routing must exist for the same line as the primary
routing.
To update demand and routing information:

order.
2. Choose Update to display the Update Demands page.
This page displays the order information including fields for Order Number,
Line Number, Assembly number, Assembly Description, Open Quantity, and
Other Quantity to Sequence.
3. To change the demand for this order, enter a new value in the Quantity to
Sequence field.
4. To change the routing to an alternate routing, select a value in the Alternate

Designator field.

Splitting Demands
You can optimize production by dividing sales order line quantities to create
multiple schedule, or splitting a quantity and moving it to another production line.
You can only split demand to an alternate routing, for a production line selected,
when you created the sequencing task. See: Selecting Production Lines for a Task
on page 6-24
To split demands on a sales order:

order.
2. Choose Split to display the Split Demands page.
This page displays the sales order information including Order Number, Line
Number, Assembly number, Assembly Description, and Quantity to Sequence
fields.
3. In the Split Quantity box, enter the quantity you want to put on a new Flow
schedule.
4. In the Split to Production Line, you have the option to select another production
line for this new Flow schedule.
The alternate routing must exist first to change the routing path

Resequencing Tasks
Resequencing Tasks
The sequencing concurrent program considers existing flow schedules within the
specified sequencing horizon—the From Start Date Time to the To End Date
Time—and re-sequences them. The resequencing of existing schedules is used in the
following situations:
■ Correct existing schedules to modify the number of hours in production, or the
quantity.
■ Relieve overloaded Flow schedules.
Flow schedules with scheduled Completion Date equal to the Start Date Time are
not considered to be within the horizon. A Flow schedule is within the horizon if
the Completion Date is greater than horizon Start Date Time, and no later than
horizon End Date Time.
You should not resequence if the concurrent program for that schedule is still
running, the broadcast sequence is sent, the traveler is printed, or the feeder line has
started.
Viewing Sequencing Tasks

The Sequencing Tasks Search page displays a table with the last ten sequencing
tasks from the Home page, for the organization selected. This page enables you to
filter your search, and access pages to create a new task or delete a task. You can
navigate to the summary and detail pages for the search results.
To search for sequencing tasks:

1. Navigate to the Sequencing Tasks Search page.
2. Select search criteria to filter your search.
You can select criteria in the following fields: sequencing task Name,
Submission Dates From and To, concurrent request Status, concurrent request
Phase, Production Line, and User Name.
3. Choose Go to display the results of your search.
If you do not select any criteria, all sequencing task records display. Records
display in a table view.

4. Choose Create Sequencing Task to create a new task. See: Creating Sequencing
Tasks on page 6-22.
5. You can select a task in the Sequencing Task Name field to view the summary
information of the task. See: Sequencing Task Summary on page 6-36. The
summary page navigates to the details page, see: Sequencing Task Details and
Results on page 6-37
6. If you want to create a task using some or all of the parameters of an existing
sequencing task, choose Create Similar Task.
This navigates to the Entering Sequencing Tasks Parameter page. The default
name displays, you can modify the necessary information. See: Entering
Sequencing Task Parameters on page 6-23

Sequencing Task Summary

The Task Summary page displays summary data for an individual task and
production line—including the available capacity for the line, the quantity
fulfilled—and the percentage of resequencing, demand, and constraint
accomplished. Choose View to see the details, see: Sequencing Task Details and
Results on page 6-37

Sequencing Task Details and Results

The Task Detail page is a view only, printable page displaying the results from your
sequencing run. This page contains regions for:
■ Sequencing Task Parameters
■ Constraints
■ Results Summary
■ Unfulfilled Demand
■ Violated constraints
■ Violated Flow Schedules
■ Other Exceptions
The Sequencing Task Parameters region displays setup details for the production
line, and parameters entered for the task. This includes production line, daily rate,

rule, constraints, demand type, and dates for demand and schedule ranges. The
Constraints region displays a list of constraints for this rule and can be used in
comparing results in the Violated Constraints list.
The Results Summary region provides a view of production line actual capacity
considered on this specific run. It excludes the capacity fixed. For example, if the
option is to fix schedules starting at the time 10:00 am, and the line time is 8:00 am
to 4:00 pm, it considers the capacity from 10:00 am to 4:00 pm.
The Constraint Satisfaction percentage displays. For example, 80 percent signifies
that of a total of 100 lines, the Flow schedules created on the first 80 lines do not
have any violations.
The Unfulfilled Demand region provides the details for the Demand Satisfaction
listed in the summary view. For example, 80 percent signifies that out of 100
quantity demands, 80 of them are scheduled.
The Violated Constraints region lists the constraints broken in this sequencing run.
Constraint violations are pushed to the end of the sequencing horizon.

The Violated Flow Schedule region displays a list of schedule numbers, their build
sequences, the number of constraints violated, and the priorities of the constraints.
The sequencing program fails when a hard constraint is violated on any newly
created schedules. Violations are ignored on existing schedules. The priority level
designates if the constraint is classified as a hard constraint—a constraints that must
be fulfilled. If these constraints are broken—or violated—Flow Sequencing stops. A
value of zero indicates a hard constraint.
The Other Exceptions region displays any other explanations for Flow schedules
not created. For example, the exception message of Invalid Build Sequence Range
indicates that no build sequences available in order to create Flow schedules.


7
Line Scheduling Workbench
This chapter describes all the elements available in the Line Scheduling Workbench
– the sequencing and scheduling interface for Oracle Flow Manufacturing. The
following topics are discussed in this chapter.
■ Overview of Line Scheduling Workbench in Flow Manufacturing on page 7-2
■ Defining Scheduling Rules on page 7-3
■ Line Scheduling Workbench Options Window on page 7-8
■ Viewing Unscheduled Orders on page 7-10
■ Viewing, Creating, and Modifying Flow Schedules on page 7-14
■ How Scheduling is Calculated on page 7-23
■ Line Scheduling Workbench Tools Menu on page 7-25
■ Other Features on page 7-32
Line Scheduling Workbench 7-1

Overview of Line Scheduling Workbench in Flow Manufacturing
Overview of Line Scheduling Workbench in Flow Manufacturing

Line scheduling is the process of sequencing and scheduling the work to be done on
your balanced flow lines. You create flow schedules to represent the volume and
mix of products to be produced. The objective of line scheduling is to synchronize
production as tightly as possible to customer demand, as well as establishing an
achievable pace and consistent flow of products throughout the production process
and supply chain.
The Line Scheduling Workbench is used by schedulers to create and manage flow
schedules. You can simulate the assignment of work to production lines, and
schedule work on specific lines. While you can view all scheduled orders (such as
discrete jobs, repetitive schedules, and flow schedules) through the workbench
windows, the only type of work you can create and schedule in the workbench is a
flow schedule.
The Line Scheduling Workbench Options window is the interface to the other
planning windows in line scheduling. The functions available through the
workbench are:
■ Viewing Unscheduled Orders
You can view unscheduled orders in the Line Scheduling Workbench
Unscheduled Orders window. You have the option to display the unscheduled
planned orders or sales orders. These unscheduled orders can be converted into
flow schedules.
■ Creating and Maintaining Flow Schedules
You can create and modify schedule quantities and dates of flow schedules.
■ Prioritizing and Sequencing Flow Schedules
You can schedule your flow schedules either by using the scheduling rules
provided, or ones that you have defined.
■ Flow Schedule Completion
You can perform completion transactions for scheduled flow schedules when
production is finished.
■ Mixed Model Map
The Mixed Model Map window can be accessed from the workbench. This
window is used to monitor your line design by balancing a line against a
specified statement of demand.

Defining Scheduling Rules
■ Roll Flow Schedules

You can roll flow schedules forward, based on undercompletions and
overcompletions, in order to adjust future production.
■ Deleting Flow Schedules
You can delete flow schedules in order to provide a clean slate for new schedule
generation.
■ Checking the Availability of Components
You can access the ATP Results window to view component availability.
■ Viewing Resource Load in Relationship to Available Capacity
You can view a graphical representation of the required load of the line and its
associated resources.

A scheduling rule determines the logic used to set the timing of the flow schedules.
The rule is comprised of an algorithm and the criteria used in sequencing the flow
schedules. Oracle Flow Manufacturing provides several types of scheduling rule
options. Pre-defined scheduling rules combine a system algorithm with sequencing
criteria. In addition, there are two methods to create your own rules.
Scheduling Rule Options

■ Pre-Defined Rules
Pre-defined scheduling rules combine a system algorithm and one sequencing
criteria. Five pre-defined rules are provided.
■ System-Defined Rules
User-defined scheduling rules allow you to combine a system algorithm with
one or more of the system provided criteria.
■ User-Defined
You can also create your own rules defined by modifying the custom line
scheduling procedure that is executed at the time of scheduling flow lines.

Scheduling Algorithms
Three algorithms are provided for line scheduling:
No Level Loading
Flow schedules are sequenced according to criteria, and the demand is placed in the
days of the scheduling horizon. Starting with the first available day, demand is
scheduled until capacity is reached.
Criteria Order is used to determine the sequence of the flow schedules. Beginning
with the demand with lowest sequence (or highest priority), demand scheduled in
ascending order.
Level Daily Rates

Flow schedules on each day are sequenced based on the demand ratio. In this
algorithm the production rate for each item is calculated for each day. Therefore,
items with higher demand have a higher production rate. That rate is then used on
each day of the scheduling horizon.
Production rate for an item on a particular day is determined by multiplying the
available capacity on that day by the demand ratio for the item.
Mixed Models
In this algorithm the production rate for different items is calculated in order to
establish a production rule pattern for a mix of items. The rule pattern is repeated
within a day and across the scheduling horizon.
Sequencing Criteria
You can sequence flow schedules using one or more of the following values:
■ Order Entry Date
■ Order Priority
■ Order Promise Date
■ Order Request Date
■ Order Schedule Date
■ Production Sequence Forward
■ Production Sequence Reverse

The criteria is listed in the order of priority. For example, you can sequence by
Order Request Date and Order Entry Date. The Order Request Date has priority 1,
the Order Entry Date has priority 2. If two different flow schedules have the same
order request date, then the order with the earliest order entry date is scheduled
first.
Criteria are only applied to unscheduled sales orders. For unscheduled planned
orders, the generated Planned Order Due Date value is the only criteria used for
sequencing.
See Also
Define Scheduling Rules Window on page 7-5
Define Scheduling Rules Window

You can view scheduling rules and sequencing criteria, as well as define your own
custom rules in this window.

To view existing scheduling rules:

1. Navigate to the Define Scheduling Rules window.
2. From the Query menu choose Enter, and then choose Run.
Use the Arrow keys to page through the list of scheduling rules.
To define system-defined or user-defined scheduling rules:

1. Navigate to the Define Scheduling Rules window.
2. Enter the name of the scheduling rule in the Name field.
If you are creating a custom rule, this value is user-defined. The following rules
are provided in the system:
■ Mixed Model - mixed model by order request date
■ Level Daily Rate- level daily rate by order request date
■ Request Date- order request date with no leveling
■ Schedule Date - order schedule date with no leveling
■ Promise Date - order promise date with no leveling
■ Production Sequence Forward - order schedule date, order production date
sequence in ascending order with no level loading
■ Production Sequence Reverse - order schedule date, order production date
sequence in descending order with no level loading
3. Enter the description of the rule in the Description field.
For rules you create, it is beneficial to have the name and description reflect the
algorithm being used.
4. Uncheck the Enabled check box if you are disabling an existing rule, otherwise
leave it marked.
This is a Yes/No flag indicating whether this rule is currently in use.
5. Select the Default check box if this rule is to be your default scheduling rule.
This is Yes/No flag indicating if this is the default rule. The default rule is used
unless it is overridden; there can only be one default rule for scheduling.
6. If this is a system-defined rule, choose the System Defined option button.
Otherwise, if this rule is to be defined by a user procedure, proceed to Step 9.

This option button enables the region for rules using system provided
algorithms and sequencing criteria.
7. Select an algorithm in the Leveling box.
The system algorithm values in this box are:
■ No Level Loading–sequencing is calculated only by priority criteria
■ Level Daily Rate–the calculation is the ratio of total demand for each item,
multiplied by the line rate
■ Mixed Model–daily demand is calculated from different products and
different lot sizes
8. In the Criteria Name box, select criteria values from the list of values.
Enter one or more values in order of priority. For example, if you select Order
Request Date first, and then Order Entry Date–the order with the earliest
request date and earliest order entry date is scheduled first.
■ Order Entry Date
■ Order Priority
■ Order Promise Date
■ Order Request Date
■ Order Schedule Date
■ Production Sequence Forward
■ Production Sequence Reverse
9. For user procedures, choose the User Defined option button.
This option button sets the rule to user-defined. To add custom line scheduling
logic, modify the Custom_Schedule procedure
(MRPPCLSS.pls/MRPPCLSB.pls).
10. Save your work.

Line Scheduling Workbench Options Window

The Line Scheduling Workbench Options window is the starting window from
which to access line scheduling options. From this window you can access the other
windows to view unscheduled orders, create flow schedules, view and modify
existing schedules.
To view unscheduled orders, create flow schedules, or modify existing

schedules:
1. Navigate to the Line Scheduling Workbench Options window by selecting an
organization and production line.
The Line Scheduling Workbench Options window displays information on the
selected line. You can access the other windows using the defaulted
information, or you can enter other values.

The Daily Production Rate is information for this production line. It is the
calculation of the Hourly Production Rate multiplied by the number of work
hours for this line. See: Set Up Steps, Oracle Work in Processing User's Guide
2. Optionally select a Schedule Group value.
The Schedule Group is defined in Work in Process. The value entered here is
used as a default for any schedules created.
3. In the Unscheduled Orders region, select the Type and Order Date ranges for
unscheduled orders.
You can select Sales Orders or Planned Orders. Sales orders are created from
Order Management transactions; Planned Orders are created from all
production MPS, MRP, and DRP plans.
TThe Order Dates range determines which orders are displayed on the Unscheduled Orders window, and signifies the period of time to consider demand for scheduling.
Note: If you create multiple plans marked as production – the

Production flag is checked on the Master Production Schedules
window or the MRP Names window– you can create duplicate
flow schedules.
TThe Order Dates range determines which orders are displayed on the Unscheduled Orders window, and signifies the period of time to consider demand for scheduling.
Note: Flow schedules are created from planned orders in the Line
Scheduling Workbench—not releases from the Planner Workbench.
The Order Dates range determines which orders are displayed on the
Unscheduled Orders window, and signifies the period of time to consider
demand for scheduling. It refers to either schedule ship date of sales orders, or
due dates of planned orders.
4. In the Scheduling region select a scheduling rule.
5. Select beginning and ending date values.
Flow schedules are created for the date ranges that you select. See: How
Scheduling is Calculated on page 7-23
6. Check the Flex Tolerances check box if you want to enable flexible tolerance
fences in your scheduling calculations.
Flexible tolerance fences provide temporary increases to capacity to handle
increases in orders. The line rate is adjusted by the tolerance fence percentage
before scheduling rules are applied. Tolerance fences are set up when creating

Viewing Unscheduled Orders
line definition. See: Defining Tolerance Fences, Oracle Work in Process User’s
Guide.
7. Choose one of the following for line scheduling functions:
■ Unscheduled Orders: Displays the Unscheduled Orders window showing all
demand that has not been converted into Flow schedules. See: Viewing
Unscheduled Orders on page 7-10
■ All Flow Schedule Details: Displays the Flow Schedule Details window
enabling you to view and modify flow schedules at the detail level of the
assembly. This function displays all open Flow schedules without regard to
the schedule dates. See: Flow Schedule Details Window on page 7-20
■ Create Flow Schedules: Creates new Flow schedules using the values selected
on the Line Scheduling Workbench Options window. See: How Scheduling
is Calculated on page 7-23
■ Flow Schedule Summary: Displays the Flow Schedule Summary window for
viewing existing schedules. See:Flow Schedule Summary Window on
page 7-18

The Unscheduled Orders window is used to view unscheduled demand - demand
that has not been converted into Flow schedules. You can change certain values and
create Flow schedules directly from this window. You can also use criteria to filter
your unscheduled orders, and create Flow schedules according to that criteria. See:
How Scheduling is Calculated on page 7-23.
To view unscheduled orders:

1. Navigate to the Line Scheduling Workbench Options window and enter values,
or use the default information.
2. Choose Unscheduled Orders to display the Find Unscheduled Orders window.

3. Enter search criteria, or leave all fields blank to retrieve all records that fit the
criteria set in the Line Scheduling Options window.
4. To filter your search, enter a search string by selecting Field values and an
operator in the Condition field.
You can use one string or several strings.
You can also select the Folder menu to customize your display and save your
Find criteria.
See: Customizing the Presentation of Data in a Folder, Oracle Applications User's
Guide, and Using Query Operators, Oracle Applications User's Guide

5. Choose Find.
The Unscheduled Orders window shows all orders for the selected order type,
date range, and filter criteria.
This window displays fields for assembly number, order date, the unscheduled
quantity, the quantity available to schedule, sales order number, and
corresponding sales order lines.
6. Choose Link to link Flow schedules to sales order lines. .See: Linking Sales
Orders to Schedules on page 7-13
7. Choose Schedule to create schedules for records selected. The Flow Schedule
Summary window displays to view schedule information of planned and
completed quantities at an aggregate level. This method enables you to create
Flow schedules according to filtering criteria, schedule rule, and line capacity.
8. Choose Implement to create schedules for all unscheduled orders selected.
These orders are scheduled without regard to the line capacity or scheduling
rules. See: How Scheduling is Calculated on page 7-23

Linking Sales Orders to Schedules

Flow schedules are created from sales order demand, planned order demand, or
created manually. Manually created schedules or schedules that have had the
demand type removed do not reference a sales order. The linking functionality
enables you to establish a reference to sales orders during Flow schedule creation -
if one does not already exist, or if it is linked to a planned order. This functionality is
accessed from the Unscheduled Orders window.
When you choose Link from the Unscheduled Orders window, sales order
quantities are matched to selected schedule quantities that fall within the date range
specified. A Note window displays the linking results:
■ Sales orders linked fully
The quantity in the sales order line matches total quantity in the Flow
schedules.
■ Sales orders linked with excess quantity
The quantity in the sales order line is less than the total quantity in the Flow
schedules.
■ Sales orders linked partially

Viewing, Creating, and Modifying Flow Schedules
The quantity in the sales order line is greater than the total quantity in the Flow
schedules. Flow schedules fulfill partial quantity of the sales order line.
■ Sales orders failed to link
Sales order is not linked to any Flow schedule.
For example, you may have sales order and unscheduled order quantities as
demonstrated in the following table. The linking process matches sales order
demand with unscheduled demand resulting in some linked orders, and others not
linked.
Unscheduled
Sales Order Flow Schedule Quantities Matched
Demand not Linked Quantities
Order1, 6 each FS1, 2 each Order1, FS1. 2
- FS2, 2 each Order1, FS2, 2
Order2, 4 each FS4, 2 each Order2, FS4, 2
Order3, 6 each FS6, 2 each Order3, FS6, 2
Order4, 8 each - Order4, 0
Order1, 6 each FS1, 2 each Order1, FS1. 2
In this example, the Note window displays these results:

■ 1 sales order linked fully (Order2)
■ 1 sales order inked with excess quantity (Order1)
■ 1 sales order linked partially (Order3)
■ 1 sales order failed to link (Order4)

You access both flow schedule summary and detail information from the Line
Scheduling Workbench Options window. This allows you to view, create, and
change flow schedules. The Flow Schedule Summary window shows schedule
information grouped by assembly and date, showing the planned and completed

quantities at an aggregate level. You can then navigate to the Flow Schedule Details
window for more information on the assembly and its components.
Note: Oracle Project Manufacturing feature of model/unit

effectivity is supported in the Line Scheduling Workbench. If this
feature is enabled, the Unit Number field is visible when viewing
unscheduled orders and passed on to new flow schedules created.
See: Model/Unit Effectivity, Oracle Project Manufacturing
Implementation Manual.
See Also
Creating Flow Schedules on page 7-15
Flow Schedule Summary Window on page 7-18
Flow Schedule Details Window on page 7-20
Creating Flow Schedules

You can create flow schedules the following ways:
■ Use the Create Flow Schedules button on the Line Scheduling Workbench
Options window. When you choose this button flow schedules are created for
all unscheduled orders that fall within the date ranges if the capacity is
adequate.
Note: If the scheduling rule is set to Do Not Schedule, unscheduled

orders are converted to flow schedules according to order dates. All
unscheduled orders in the specified date range are converted to
flow schedules – schedule dates, capacity, and sequencing criteria
are ignored.
■ Use the Implement button on the Unscheduled Orders window. Flow schedules
are created for all unscheduled orders that you have selected on this window.
These orders are scheduled without regard to the line capacity or scheduling
rules.
■ Choose Schedule on the Unscheduled Orders window. This method enables
you to create Flow schedules according to filter criteria.

■ Modify the schedule on the Flow Schedules Summary window. If a schedule

quantity is added to a day that does not already have a flow schedule, one is
created.
■ You can add a new record on the Flow Schedules Details window.
To create flow schedules from the Line Scheduling Workbench Options

window:
1. Navigate to the Line Scheduling Workbench Options window.
2. You can use the default information on this window, or enter values. See: Line
Scheduling Workbench Options Window on page 7-8.
Flow schedules for a given line are sequenced within a Schedule Group,
schedules without a schedule group are sequenced together.
The Order Date ranges are used for the period of time to consider demand for
scheduling. Flow schedules are created for unscheduled orders that fall within
this date range – if the capacity is adequate.
3. Choose Create Flow Schedules.
Flow schedules are created from unscheduled orders by considering the
following elements:
■ The demand for the order type within the specified date range in the
Unscheduled Orders window.
■ The orders topmost in priority, based on sequencing criteria
■ The line capacity for the date range. If there is not enough capacity, the
order remains unscheduled.
The results of this process are shown in the Flow Schedule Summary window.
If you choose Unscheduled Orders, you can see the orders that were not
converted into flow schedules.
4. Save your work.
To convert unscheduled orders to flow schedules:

1. Navigate to the Unscheduled Orders window.
2. Select the records to implement into flow schedules.

You can make any modifications or adjustments to the details of your records.
You can select multiple assemblies on this window for viewing on the detail
window. See: Selecting Multiple Records, Oracle Applications User's Guide.
Flow schedules are created for all unscheduled orders that you have selected on
this window. These orders are scheduled without regard to the line capacity or
scheduling rules
3. Choose Implement.
4. Choose OK. Otherwise, to cancel this transaction, choose Cancel.
5. Choose Yes to view the Flow Schedule Details window with the new schedule
record. Choose No to view the Unscheduled Orders window.
After the new schedule is created, the demand does not appear on the
Unscheduled Orders window.
6. Save your work.
7. Choose Schedule to create schedules for records selected. The Flow Schedule
Summary window displays to view schedule information of planned and
completed quantities at an aggregate level. This method enables you to create
Flow schedules according to filtering criteria, schedule rule, and line capacity.
To create flow schedules by modifying information on the Flow

Schedules Summary window:
1. Navigate to the Flow Schedules Summary window.
Only schedules without details (such as schedule group, project, or task) can be
modified at the summary level. If details exist, the Flow Schedule Details
window appears.
2. Enter the new planned quantity, or scroll to the date you to modify and update
quantity. You can only modify the Total Planned Quantity, not the completed or
variance value.
3. Save your new record.
If a schedule quantity is added to a day that does not already have a flow
schedule, a new record is created for that day.
Attention: If the quantity is changed to 0, the flow schedule is

deleted – but you cannot delete flow schedules with partial or full
completion status.

To create flow schedules by adding a new record on the Flow Schedule

Details window:
1. Navigate to the Flow Schedule Details window.
2. Enter the record information and save your record.
You can add flow schedules only for the line you have specified on the Line
Scheduling Workbench Options window.
Flow Schedule Summary Window

The Flow Schedule Summary window is used to view and manage flow schedules
at an aggregate level. This window shows all flow schedules, discrete jobs, and
repetitive schedules at a summary level.
Note: Only flow schedules can be maintained through this

window. Repetitive schedules and discrete jobs are displayed but
cannot be modified.
To view or modify flow schedules at a summary level:

2. You can use the default information on this window, or enter values. See: Line
Scheduling Workbench Options Window on page 7-8.
Schedule quantities can be modified in both the summary and detail windows.
However, only schedules that do not have details (such as schedule group,
project, or task) can be modified at the summary level.
3. Choose Flow Schedule Summary
The Flow Schedule Summary window shows schedules, in a bucketed format,
from the start dates selected on the Line Scheduling Workbench Options
window. You can scroll back or forward in this window.

Three types of order information can be viewed. You can select the types
displayed on this window through Preferences in the Tools Menu. See:
Preferences on page 7-31
■ Planned quantity is calculated when the flow schedule is created, this
amount can be changed.
■ Completed quantity is updated when you perform a completion on this
schedule.
■ Variance is the difference between Planned and Completed quantities.
4. To modify a flow schedule quantity, change the Planned quantity in the date
column selected. However, only schedules that do not have details (such as
schedule group, project, or task) can be modified at the summary level.
The Total and Total Planned Quantity for this assembly reflect the changes you
just made.
This window offers the feature of spreading weekly quantities across the valid
workdays. Enter a value in the Total field, and choose Tab.

The new total quantity will spread even across all the workdays and display in
the window.
5. Save your work.
6. You can access the following windows:
■ Unscheduled Orders: Displays the Unscheduled Orders window. See:
Viewing Unscheduled Orders on page 7-10
■ Details: Displays the Flow Schedule Details window for the assemblies and
dates selected. The number after the word Detail indicates how many
records are selected. You can select multiple assemblies on this window for
viewing on the detail window. See: Selecting Multiple Records, Oracle
Applications User's Guide, and Flow Schedule Details Window on page 7-20
Flow Schedule Details Window

The Flow Schedule Details window enables you to view and modify Flow
schedules at the detail level of the assembly. You can access this window from the
Line Scheduling Options or Flow Schedule Summary windows. If you are
navigating from the Line Scheduling Options window, you can filter your search by
entering field and operator values. All details within criteria specified display on
the Flow Schedule Details window. If you are accessing this window from the Flow
Schedule Summary window, only the schedules selected display.
Note: Only flow schedules can be maintained through this

window. Repetitive schedules and discrete jobs are displayed but
cannot be modified.
To view or modify flow schedule details:

2. Enter values, and choose All Flow Schedule Details. See: Line Scheduling
Workbench Options Window on page 7-8
The Find Flow Schedule Details window displays.
3. Enter search criteria, or leave all fields blank to retrieve all records.
4. To filter your search, enter a search string by selecting Field values and an
operator in the Condition field
You can use one string or several strings.

You can also select the Folder menu to customize your display and save your
Find criteria.
See: Customizing the Presentation of Data in a Folder, Oracle Applications User's

Guide, and Using Query Operators, Oracle Applications User's Guide
5. Choose Find.
The Flow Schedule Details window displays information according to your
search criteria.
To select specific Flow schedule details from the summary window:

1. Navigate to the Flow Schedule Summary window, select one or more
assemblies.
2. Choose Details.
The Flow Schedule Details window displays information on the assemblies
selected in the summary window.
To view or modify Flow schedule details:

This window displays fields for Assembly, Build Sequence, Completion Date,
Quantity, Completed Quantity, Order Number, Order Line, Order Requested
Date, and Unit Number.

2. You can modify some values including Build Sequence, Completion Date, and
Quantity fields.
3. Save your work.
4. You can access the following windows:
■ Unscheduled Orders: Displays the Unscheduled Orders window. See:
Viewing Unscheduled Orders on page 7-10
■ Component Availability: Displays the ATP Results window to show the status
of material used on your lines. See: Component Availability on page 7-32
Component availability checking is permitted only for items with the Check
ATP item attribute set to Yes. See: Order Management Attribute Group,
Oracle Inventory User's Guide

How Scheduling is Calculated

Scheduling rules determine the timing of the flow schedules. using the following
logic in the calculation routine:
■ Sequence is determined by the criteria in the rule.
Demand is sequenced using the criteria in the scheduling rule. The priority of
each criteria determines the order in which it is applied.
■ The first flow schedule created goes to the first available date in the scheduling
horizon.
Flow schedules are created for orders starting with the first available due date
that has capacity. Flow schedules are not created for orders than cannot be
scheduled within the scheduling horizon.
■ This process of attaining the line rate for each day continues until the end of the
scheduling horizon.
Capacity is calculated for the day using the line rate, subtracting the existing
workload (flow schedules, discrete jobs, repetitive schedules) for that day.
When available capacity for the day is attained, schedules are slated for the next
day until the end of the scheduling horizon.
■ If you are using flexible tolerance fences, scheduling begins after the last day
indicated from the Days in Advance value.
Tolerance fences provide temporary increases to capacity above their normal
operating rate to handle rises in orders.
Algorithms
The scheduling rule is comprised of an algorithm and the criteria used in
sequencing the flow schedules. Oracle Flow Manufacturing provides three
algorithms described here.
■ No Level Loading
If you select a scheduling rule that has no level loading, the criteria defined in
the scheduling rule is used to prioritize and sequence the orders. Orders are
scheduled with capacity considerations beginning with the first available date
of the scheduling date range. If the entire quantity of the sales order cannot be
satisfied on a date, the remaining quantity is scheduled on subsequent days
where capacity is available.
■ Level Daily Rate

If you choose to schedule for each day using the level daily rate, each item is
scheduled at a rate in regard to the demand ratio of the item. The demand ratio
of an item equals the total demand of the item divided by the grand total
demand.
■ Mixed Model
This algorithm establishes a pattern to manufacture items in order to meet
demand. The pattern distributes units according to the demand of each item for
each day.

Line Scheduling Workbench Tools Menu

The following are functions available in the Tools Menu for maintaining flow
schedules. This menu is available through any of the windows in the Line
Scheduling Workbench.
■ Completions
■ Mixed Model Map
■ Roll Flow Schedules
■ Delete Flow Schedules
■ Preferences
Completion of Flow Schedules

You can complete flow schedules through the Work Order-less Completions
window. Choose Completions from the Tools menu to display the window. The
details of the schedules you selected are defaulted in the Work Order-less
Completions window.
See Also
Performing Work Order-less Completions, Oracle Work in Process User's Guide
Mixed Model Map

You can access the Mixed Model Workbench from the Tools menu. The Mixed
Model Map Workbench helps you to create and monitor your line design by
balancing a line against a specified forecast.
You can use the Mixed Model Map to compare line information with demand
requirements. This provides information to adjust resources on the line to meet the
demand. The output of the Mixed Model Map will give you the line rate.
Roll Flow Schedules

You must maintain flow schedules so that production schedule information is
accurate; and planning information such as Available-To-Promise and demand for
components is current. The Roll Flow Schedules program is designed to allow you
to adjust future schedules based on actual performance in the past. You adjust the
quantity on future production schedules based on the completion quantities and

past production. You can change schedules for a line, a range of lines, or for all lines
at once.
Attention: MRP calculations does not consider flow schedules

with past due dates. Use the Roll Flow Schedules window to
update your flow schedules in order to keep your MRP accurate.
Note: The Feeder Line Synchronization program ignores flow

schedules created from the Roll Flow Schedules program. You must
roll schedules on both the parent and feeder lines.
Three options are available for adjusting schedules:
Close All Past Schedules

This option closes all open past due schedules.
Note: Schedules are automatically closed when the completion

quantity is greater than or equal to the planned quantity.
Closed flow schedules cannot be changed or rolled with details, and they are
denoted with gray fields. You can close individual or a group of schedules. For
example, a customer might reduce the order quantity because a delivery date can
not be made. The original schedule is closed and the program does not roll the
excess quantity no longer needed.
Roll With Details

This option rolls any open schedules within the specified date range to a single
date. The new schedules maintain the original schedule details including the order
information, build sequence, and alternate bill of material or routing information.
The rolled schedules are scheduled at specific times if no schedules exist on the
rolled to date.
Note: The original schedules are closed after the roll. Therefore
the same schedule number cannot be rolled multiple times, nor can
you change the original schedule once it has been rolled.

Spread Evenly Without Details

You can spread schedules without order information evenly across multiple days,
for use in a repetitive environment, allowing you to:
■ Calculate variance and roll by line and item
■ Consider both the planned quantity and the completed quantity when rolling
over-completions
■ Schedule specific times for the rolled schedules if no schedules exist on the
specific rolled day
Attention: When rolling flow schedules with out details, if you

roll the same flow schedules multiple times, it is possible to create
excess supply.
To roll flow schedules forward:

1. Select Roll Flow Schedules from the Tools menu.
The Roll Flow Schedules Parameters window appears.
2. Select an Option.
Your choices are:
Close All Past Due Schedules
Roll with Details
Spread Evenly Without Details
3. Select an Output option.
The values for Output are:
Report Only creates a report but does not update your flow schedules. This
could be used to simulate the effects on your schedule.
Report and Update creates a report and rolls the dates forward on your
schedules.

4. Select a range of Start and End Dates From.

Flow schedules that do not have completion dates within this range are not
rolled forward. You cannot enter a date in the From Start Date greater than
today.
5. Select a range of Start and End Dates To.

6. You can select a range of flow schedule lines to consider in the Lines From and
To fields.
Attention: If you do not specify lines, item numbers, or categories

all flow schedules that fall within the specified date ranges are
rolled forward.
7. Select a range of assembly items to consider in the Items From and To fields.
8. Select a range of Category Sets From and To.
9. Choose OK.
10. Choose Submit Request.

See Also
Submitting a Request, Oracle Applications User's Guide
Deleting Flow Schedules

You can delete flow schedules in order to provide a clean slate for new schedule
generation. Flow schedules can be deleted as long as the following conditions are
true:
■ There has been no completion performed, that is, the quantity completed must
equal 0.
■ The schedule is open.
■ There is no pending completion against it in Material Transactions Interface.
If the deleted flow schedule is associated with a sales order, then that portion of the
sales order is again considered as an unscheduled sales order.
To delete flow schedules:

1. Select records on the Detail or Summary windows, and choose Delete.
2. 2.You can also select Delete Flow Schedules from the Tools menu.

The Delete Flow Schedules Parameters window appears.

3. Select a range of Dates Start and From.
Flow schedules that do not fall within this range of dates are not deleted.
4. Optionally, select a range of Lines From and To.
Note: If you do not specify lines, item numbers, or categories all

eligible flow schedules that fall within your specified date ranges
are deleted.
5. Optionally, select a range of Items From and To.

6. To delete flow schedules by category, select a value in the Category Set field,
and enter a range of categories Category From and To.
7. Choose OK.
See Also
Submitting a Request, Oracle Applications User's Guide
Defining Category Sets, Oracle Inventory User's Guide

Preferences
The Preferences window is used to change the quantity types that show on the Flow
Schedule Summary window.
The Planned quantity is originally calculated when the flow schedule is created
using the rule and available capacity. The Completed quantity is updated when you
perform a completion on this schedule. The Variance is the difference between
Planned and Completed quantities.

Other Features
Other Features
Component Availability
You can access Available To Promise information through the ATP Results window
and view the status of material used on your flow schedules. Component
availability checking is permitted only for items with the Check ATP item attribute
set to Yes. See: Order Management Attribute Group, Oracle Inventory User's Guide
To display the ATP Results window:

2. Select assemblies for viewing component information.

3. Choose Component Availability.
The ATP Results window appears. The components for each flow schedule are
listed individually on separate rows. See: Viewing ATP Results, Oracle Inventory
User's Guide

Other Features
Purging Flow Schedules

Closed flow schedules should be purged on a periodic basis to remove unneeded
records and maintain database performance. A concurrent program purges
according to parameters specified.
Flow schedules are purged if they meet the following criteria:
■ Status of the flow schedule is closed
■ Scheduled completion date of the flow schedule is in a closed accounting period
■ All material transactions have been purged
To purge flow schedules:

1. Navigate to the Purge Flow Schedules window.
The Parameters window displays.
2. Select the effective date to use for purging schedules in the Cut-Off Date field.
Flow schedules with a completion date prior to the cutoff date are purged.
3. Optionally, you can select a value in the Line field to purge specific flow lines.
4. You can also select a specific assembly in your purging criteria.

5. Choose OK to display the Purge Flow Schedule request window.
6. Choose Submit to create this request.

Other Features

8
Feeder Line Synchronization
This chapter describes the feeder line synchronization process.
Feeder Line Synchronization 8-1


In manufacturing environments where many types of items are produced, the total
amount for different configurations of a product may not be sufficient to support a
Kanban replenishment system. Oracle Flow Manufacturing resolves this situation
by enabling you to create schedules for lines that are directly derived from parent
assembly line schedules. These feeder lines use sequence information from the
parent assembly schedules so that you can synchronize the higher and
sub-assembly material with production.
The feeder line synchronization program calculates the date and time the
subassembly is delivered to the particular line operation. This date is then be used
as the completion date for the subassembly line. The completion date of the feeder
line flow schedule is calculated as the difference between the parent assembly's
scheduled completion date and the sum of the operation times. This is the sum of
the operation times from the consuming operation to the end of the parent line.
The start time for the subassembly is calculated by subtracting the lead time from
the completion date and time. Lead time is obtained from fixed lead time and
variable lead time on the organization item. This allows you to synchronize
subassembly lines to deliver product exactly when needed by the main line.
You cannot create new synchronized schedules if corresponding schedules already
exist on the feeder line. You also cannot re-synchronize rolled schedules. This
eliminates potentially creating over production of the subassembly.
Prerequisites
❏ Create flow routings and routing networks for both the parent and subassembly
items.
❏ Define the operation sequence for the subassembly on the bill of material of the
parent item. This must be equal to the event sequence on the parent routing of
the event consuming the subassembly.
❏ Define the variable lead time on the organization item master for each item to
equal the TAKT time of each line, respectively.
❏ Define the fixed lead time on the organization item master for each item to
equal the total product cycle time (TPCT) or the TAKT time of the line
multiplied by the number of operations along the longest primary path of the
line.

❏ Define the maximum hourly rate on the line definition for both the parent and
feeder line the same as the standard daily running rate for each line,
respectively.
To create flow schedules that synchronize feeder lines with parent

assembly lines:
1. Navigate to the Feeder Line Synchronization window.
The Parameters window appears.
2. Select a parent line or range of Lines From and To.
3. Select a range of Dates From and To.

This is the date range of the start dates of the parent assembly schedule; it is
used to determine which parent schedules are synchronized.
4. Choose OK.
Feeder Line Synchronization 8-3


9
Outbound Broadcast Sequencing
This chapter describes Outbound Broadcast Sequencing—a process that enables the
creation of replenishment signals on a Flow line where the supplier has special
requirements, preferences, or conditions.Topics include:
■ Overview of Outbound Broadcast Sequencing on page 9-2
■ Setting Up Outbound Broadcast Sequencing on page 9-2
■ Process Flow on page 9-3
Outbound Broadcast Sequencing 9-1

Overview of Outbound Broadcast Sequencing
Overview of Outbound Broadcast Sequencing

Outbound Broadcast Sequencing is a process that enables the creation of
replenishment signals to supply components for scheduled assemblies, dependent
on the production sequence of the respective parent assembly. Although generally
associated with supplier components, this process works with all methods of
kanban supply.
Kanban signals control the replenishment of component material to a Flow line.
Kanban planning has calculated container sizes, or quantity based on a predictable
cycle, ensuring the availability of all necessary components. In some business
processes the predictability of components is not possible, or the schedule of
assemblies determines the component requirements. Outbound Broadcast
Sequencing provides a method for sourcing components. For these components, the
purchase requisition is generated based on firm Flow schedules. This functionality
is implemented when you set up pull sequences with the Auto Request flag
enabled.
A concurrent program is used to calculate kanban requirements and generate
kanban cards by specifying production lines, date ranges, and other criteria. The
Outbound Broadcast Sequencing process sends the appropriate date for creation of
the purchase requisition for the relevant components, depending upon the Source
type specified in the item’s pull sequence.
See Also
Overview of Kanban Replenishment, Oracle Inventory User’s Guide.
Defining Kanban Pull Sequences, Oracle Inventory User’s Guide
Setting Up Outbound Broadcast Sequencing on page 9-2
Process Flow on page 9-3
Setting Up Outbound Broadcast Sequencing

Outbound Broadcast Sequencing functionality is set up when you create your pull
sequences.
❏ Pull Sequence window
Enable the Auto Request box, this is used to identify this type of pull sequence
replenishment.

Process Flow
Note: The size and number of kanban cards are not used for
kanban calculation, if the Auto Request box is enabled.
See Also
Modifying and Creating Pull Sequences on the Graphical Network on page 11-10
Pull Sequence Window on page 11-12
Defining Kanban Pull Sequences, Oracle Inventory User’s Guide.
Process Flow
The following steps are performed when Outbound Broadcast Sequencing kanbans
program is initiated:
■ Retrieves Flow schedules in the date range specified.
■ Selects Flow schedules not previously processed.
■ Considers schedules with components flagged as Item Attribute--Release
Time Fence, Kanban Item--Do Not Plan, and Supply Type—Pull.
■ Considers pull sequences where item and point of use matches the bill of
material, component, location, and the Auto Request flag is enabled.
■ Calculates required date of the components based on the Flow schedule
completion date and the routing where the component is used. Minimum order
quantity data is not used.
■ Creates nonreplenishable kanban cards for the components using the pull
sequence information.
■ For kanban card supply type Supplier, the purchase requisition is created with
the reference to the Flow schedule information. For other supply types—
See Also
Changing and Viewing Kanban Details on page 11-25.
Viewing Kanban Demands on page 11-25
Using the Kanban Calculation Program, Oracle Master Scheduling/MRP and Oracle
Supply Chain Planning User’s Guide.
Defining Kanban Cards, Oracle Inventory User’s Guide
Outbound Broadcast Sequencing 9-3

Process Flow

10
This chapter describes the Flow Execution Workstation—used to track the flow of
shop floor work, view schedule and line operation information, and complete
schedules. The following topics are included:
■ Overview of the Flow Execution Workstation on page 10-2
■ Setting Your Preferences on page 10-2
■ Initializing the Flow Execution Workstation on page 10-8
■ Viewing Schedule Information on page 10-13
■ Viewing Event Information on page 10-15
■ Completing Line Operations on page 10-16
■ Completing Schedules on page 10-19
■ Viewing Resources on page 10-20
■ Attaching and Viewing Instructions on page 10-21
■ Viewing Detail Properties on page 10-25
■ Viewing Components and Replenishing Kanban Cards on page 10-26
■ Integration with Oracle Quality on page 10-27
■ Customized Properties Region on page 10-28
■ Engineering Change Order Alerts on page 10-28
Flow Execution Workstation 10-1

Overview of the Flow Execution Workstation
Overview of the Flow Execution Workstation

The Flow Execution Workstation is a web based workstation providing a
comprehensive set of features for tracking the flow of work, completing assemblies,
and viewing details of component and resource information. The workstation has
regions for schedules, events, component details, property information, and
instructions. The features include the ability to:
■ View current shop floor manufacturing work
■ View a line operation’s open schedules and events
■ View detailed information on the components and resources required for line
operations and events
■ View kanban information for components and request replenishment
■ View operating instructions, diagrams, and other information attached to
assemblies and events
■ Complete line operations and schedules
■ Specify alternate or rework routing paths while performing completions
■ Customize personal display of information
■ Check eligible Oracle Bills of Material engineering change orders (ECOs) for
line operation or event component changes
■ Create a region to display your own customized parameters not included in the
workstation pages.
■ Access Oracle Quality collection plans
Setting Your Preferences

Data display on the workstation is controlled by preferences selected in the Edit
Preferences page. Preferences and corresponding behavior are defined for
organization, production line, or line operation. The preference for a parameter
setting determines the data entry mode, the display of regions and fields on your
pages, ECO checking, and the ability to enable other workstation locations.
When you enter parameters in the Flow Execution Workstation, the system first
searches for records with the most detail specified at the line operation level. If the
operation level parameter is not defined, it searches one level up at the line level. If
production line is not specified, the system uses the organization level defaults.

To set or view preferences in the Flow Execution Workstation:

1. In the Flow Manufacturing Sequencing and Execution Home page, select the
Setup tabbed region.
2. Select Workstation Preferences to display the Select Preferences page.
3. Specify preference parameters.
You are required to select an organization, line and operation are optional:
■ Organization: If only organization is specified, the data preference is
defined at the organization level only.
■ Production Line: If organization and line are specified, the data preference
is defined for a specific organization and production line combination.
■ Line Operation: If organization, production line, and line operation are
specified; the data preference is defined for a specific organization, line, and
line operation combination.
4. Choose Edit to display the Edit Preferences page.

If the parameter or parameter combination specified does not exist as a
preference, a new one is created using default values. You can change the values
for either new or existing preferences on the Edit Preferences page.

5. Set your preference for the Workstation Enabled box.

This parameter specifies if the workstation is used at this particular
organization, line, or operation. If set to:
■ Enabled: The workstation displays applicable Flow schedules and the
operator is required to choose Line Operation Completion.
■ Disabled: A workstation is not used at this specific organization, line, or
operation.
6. In the Settings region, Schedule Selection Mode, select how schedules display
on the workstation. Your choices are:
■ Work Queue: You can provide search criteria, and display the resulting list
of schedules and their corresponding events.
■ User Entered: You can search, enter, or scan (using a mobile device) a
specific schedule number to open the Line Operation page.
7. If the Schedule Selection Mode is set for Work Queue mode, set the Automatic
Schedule Transition field.
Used to specify navigation options for line operations. Your choices are:
■ Yes—after choosing Complete Line Operation, the next available schedule
displays on the page.

■ No—after choosing Complete Line Operation, the Work Queue page

displays listing the available schedules for the next transaction.
Note: The Used Entered mode does not use this setting because
the next available schedule is always user specified.
8. In the Automatic ECO Check, indicate if you want the system to automatically
check for eligible Engineering Change Orders. Otherwise, you can check for
ECOs manually. Select Yes or No.
9. When you check for ECOs. you can indicate a range of days to check before and
after the ECO Effective Date. In the ECO Days Prior and ECO Days After, enter
the number of days.
Only Implemented ECOs in the date range are considered. See: Engineering
Change Order Alerts on page 10-28
10. In the Instruction Frame Height field, set the view size of attachments on the
pages. Enter a pixel value to increase or decrease the size of the display. See:
Attaching and Viewing Instructions on page 10-21
11. If this preference is defined at the line level, you can define specific transactions
performed at line operation completion. These fields are available only at the
line level preference.
■ Pick Release Operation: Operation where the Pick Release process is called.
See: Component Pick Release, Oracle Work in Process User’s Guide.
■ Label Start and End Operation: Label printing capabilities are available at
the time of completion for various types of manufacturing information. If
you have defined label types at the Flow line Start or Flow line operation,
labels are printed. See: Compliance Labeling Setup, Oracle Warehouse
Management User’s Guide.
12. In the Line Operation and Event tabbed regions—select how you want the page
regions, tabbed regions, and instructions to display on the pages. In Page
Regions, choose the regions that display on the Line Operation and Event
pages.

Select categories from the Available box—and move to the Selected box. For
example:
■ In the Line Operation tabbed region, if the Events and Tabs are in the
Selected box—the Line Operation page displays an Events region, and
tabbed region.
■ If the Events, Instructions, and Tabs are in the Selected box—the Line
Operation page displays the Events region, the Instruction region, and
tabbed region.
■ In the Event tabbed region, if the Components and Tabs are in the Selected
box—the Event page displays a Components region, and tabbed region.
See: Viewing Schedule Information on page 10-13 and Viewing Event
The regions available for line operations and events page regions are
Instructions, Components, Resources, Schedule Properties, and Customized
Properties, Tabs, and Events (for Line Operation only). The order listed in the
Selected box, is the order they display on the page. Use the Arrow tool to
change the order.
Regions are displayed only in one mode. That is, a region is only displayed
either as a region on a page, or a region on a tabbed region. It is not diaplayed
in both areas.

13. In Tab Regions, choose the regions to display on the Line Operation and Event
pages.
Select fregions from the Available box—and move to the Selected box. The
order listed in the Selected box, is the order they display on the tabbed region.
Use the Arrow tool to change the order.
14. In the Instructions boxes, select entity attachments to automatically display in

the Instructions region.
Select attachment sources from the Available box—and move to the Selected
box. The order listed in the Selected box, is the order they display on the page.
Use the Arrow tool to change the order. See: Attaching and Viewing
Instructions on page 10-21, and Attachments, Oracle Applications User’s Guide
Note: All Available attachments are viewable. The Selected

attachments automatically display.

Initializing the Flow Execution Workstation

The Flow Execution Workstation is initialized by selecting an organization,
production line, and line operation. The preference determines if the workstation
displays a listing of Flow schedules (the Work Queue)—or you manually enter or
scan information (the User Entered mode). See: Setting Your Preferences on
page 10-2
The Work Queue mode opens the Work Queue Search page where you can select
search criteria. From these results, select a schedule from the Work Queue list to
access the Line Operation page. The User Entered mode navigates directly to the
Line Operation page for the line and operation entered.
The Line Operation page enables you to view individual schedules, operations,
events, and instructions. You can complete schedules and line operations, and enter
quality results.
To view and enter Flow schedule details in the Workstation:

1. Navigate to the Flow Execution Workstation.
The Flow Execution Workstation Startup page displays for selecting schedule
parameters.

2. Select parameters for Organization, Production Line, and Line Operation.

The Workstation preference for the organization, line, and operation determines
the entry mode: If the mode is:
■ Work Queue: You can provide search criteria, and display the resulting list
of schedules and corresponding events. See: Work Queue Mode on
page 10-10
■ User Entered: You can search, enter, or scan a specific schedule number to
open the Line Operation page. See: User Entered Mode on page 10-12

Work Queue Mode
To access Flow Execution Workstation pages in Work Queue mode:

1. Navigate to the Flow Execution Workstation, and select parameters to display
the Flow Execution Workstation Startup page.
2. The Work Queue Criteria page displays. Select any criteria for filtering your
flow schedule search.
You can define your search by selecting values, or a range, in the following
fields—Completion Date, Assembly, Schedule Group, and Build Sequence.
3. Choose Start to display the Work Queue page.

The work queue consists of a list of schedules and events for a selected
schedule. You can perform completions of line operations and schedules from
the work queue.

In the Flow Schedules region, this page displays Schedule Number, Assembly
Part Number, Build Sequence, Planned Quantity, and Completion Date.
■ Planned Quantity field value is the quantity created when the schedule is
created; it does not change.
■ Completion Date field value is the scheduled completion date of the flow
schedule; it does not change with the actual completion of line operation or
flow schedule.
The fields in the Events region are Event Sequence, Operation Code, Event
Description, and Department. See: Viewing Event Information on page 10-15
4. To navigate to the Line Operation page, select a schedule by enabling the radio
button in the Select column—and choose Get Schedule.
You can also select the schedule number. See: Viewing Schedule Information on
page 10-13
5. To navigate to the Event page, select a schedule by enabling the radio button in
the Select column—and choose Get Event
You can also select an event sequence. See: Viewing Event Information on
page 10-15

6. To complete schedules or line operations from this page, choose either

Complete Schedule or Complete Operation in the row for the selected schedule
number.
When a schedule is completed, it is no longer shown on the work queue. See:
Completing Line Operations on page 10-16, and Completing Schedules on
page 10-19
User Entered Mode
To access Flow Execution Workstation pages in User Entered mode:

1. Navigate to the Flow Execution Workstation, and select parameters to display
the Flow Execution Workstation Startup page.
2. Choose Start to display the Enter Schedule page.

3. In the Schedule Number field, search, enter, or scan a specific schedule number.
4. Choose either Get Schedule or Get Event to access the schedules and events for
this Flow schedule.
See: Viewing Schedule Information on page 10-13 and Viewing Event

Viewing Schedule Information

The Line Operation page displays schedule information in the General region. This
includes fields for Schedule Number, Build Sequence, Assembly Item, And
Scheduled Quantity.
Other information is displayed as a region or tab, depending on the preference

setting. This includes events, instructions, components, resources, detail properties,
and customized properties. See: Setting Your Preferences on page 10-2
The Line Operation page enables you view and perform transactions for Flow
schedules including:
■ View the schedules corresponding event information. See: Viewing Event
■ View details of resources attached to events, for this line operation and
schedule. See: Viewing Resources on page 10-20
■ View detail information about the line schedule. See: Viewing Detail Properties
on page 10-25
■ View and replenish components using Kanban cards See: Viewing Components
and Replenishing Kanban Cards on page 10-26

■ Complete schedules and line operations. See: Completing Line Operations on

page 10-16, and Completing Schedules on page 10-19
■ Enter quality data results for mandatory or optional collection plans, at specific
points on a routing. See: Integration with Oracle Quality on page 10-27
■ Check ECOs to insure you have the correct changes for work as it progresses.
See: Engineering Change Order Alerts on page 10-28.
■ Display a table of all attached instructions and documents pertaining to the
assembly and schedule. You can then view each individual document. See:
Attaching and Viewing Instructions on page 10-21
■ View a region of custom parameters created to fit your business needs. See:
Customized Properties Region on page 10-28

Viewing Event Information
Viewing Event Information

The Event page displays the event sequence information in the General region. This
includes the corresponding Flow schedule, the item assembly number, build
sequence, and schedule quantity.
Other information is displayed as a region or tab, depending on the preference
setting. This includes instructions, components, resources, detail properties, and
customized properties. See: Setting Your Preferences on page 10-2

Completing Line Operations
The Event page enables you view and perform transactions for Flow schedules.
Navigate between consecutive events by choosing Next. This enables you to display
sequential events in order performed, until the line operation is completed.
■ View details of resources attached to events, for this line operation and
schedule. See: Viewing Resources on page 10-20
■ View detail information about the line schedule. See: Viewing Detail Properties
on page 10-25
■ View and replenish components using Kanban cards. See: Viewing Components
and Replenishing Kanban Cards on page 10-26
■ View a region of custom parameters created to fit your business needs. See:
Customized Properties Region on page 10-28
■ Complete schedules and line operations. See: Completing Line Operations on
page 10-16, and Completing Schedules on page 10-19
■ Enter quality data results for mandatory or optional collection plans, at specific
points on a routing. See: Integration with Oracle Quality on page 10-27
■ Check ECOs to insure you have the correct changes for work as it progresses.
See: Engineering Change Order Alerts on page 10-28.
■ Display a table of all attached instructions and documents pertaining to the
production line. You can then view each individual document. See: Attaching
and Viewing Instructions on page 10-21

You can perform line operation completions from either the Work Queue, Line
Operation, or Event pages.
Line operations with one destination, and no existing mandatory Oracle Quality
plans, those completions are performed automatically when you choose Complete
Operation. If the line operation has a network of possible choices—that is primary,
alternate, and rework operations—the Line Operation Completion page displays to
select the path. This page also displays if Quality plan data needs to be entered for
the operation. You can then access the Enter Quality Results window to enter data.

To perform a completion for a line operation:

■ If your preference is Work Queue mode, you can complete line operations
from the Work Queue page. the Line Operation page, or Event page. Select
a record for completion.
■ If your preference is in the User Entered mode, completions are performed
in the Line Operation or Event page.
2. Choose Complete Line Operation.
For line operations with one destination and no existing Quality plans, the
completion transaction is performed.The Work Queue mode no longer displays
the completed line operation. A confirmation message displays.
For line operations with several routing options or existing Quality plans, the
Line Operation Completion page displays.
3. If Quality information needs to be entered, a message displays. Choose Enter
Quality Results to access the Quality Results window.
You can add data results for mandatory or optional collection plans, at specific
points on a routing. See: Integration with Oracle Quality on page 10-27, and
Entering Quality Results Directly, Oracle Quality User’s Guide.

4. If this line operation has a choice of destinations, choose the destination.

Options are primary, alternate, and rework operations.

A confirmation message displays when the line operation is completed.
See Also
Completing Schedules on page 10-19

Completing Schedules
Completing Schedules
You can perform schedule completions from either the Work Queue or the Line
Operation page. The Work Order-less Completions window is accessed where you
can enter details, and navigate to any existing quality plans for the schedule.
To perform a completion for a schedule:

■ If your preference is Work Queue mode, you can complete schedules from
the Work Queue, Line Operation, or Event pages. Select a record for
completion.
■ If your preference is in the User Entered mode, completions are performed
in the Line Operation or Event pages.
2. Choose Complete Schedule.
The Work Order-less Completions window displays, enter the appropriate data.
See: Work Order-less Completions, Oracle Work in Process User’s Guide
See Also
Completing Line Operations on page 10-16

Viewing Resources
Viewing Resources
The Resources region provides the details of resources attached to events for a
selected schedule. Resources include employees, machines, outside processing
services, and physical space. A list of resources is displayed in view-only mode and
includes information for event sequence, resource sequence, type, code, description,
basis, usage, and availability.
This feature enables you to track what is actually being used at the line operation,
and to view the time an assembly spends at an operation. The information is
derived from the Resources and Operation Resources windows in Oracle Bills of
Material.
See Also:
Defining a Resource, Oracle Bills of Material User’s Guide
Assigning Operation Resources, Oracle Bills of Material User’s Guide

Attaching and Viewing Instructions

The Flow Execution Workstation provides the ability to display attached
instructions and documents pertaining to your production. This can include
procedures, diagrams, and assembly instructions. Instructions are viewable from
the Schedule and Event pages. The attachment displays in a frame, the size can be
changed in the Edit Preferences page. If more than one attachment exists,
documents are displayed in a table format.You can specify the order of display in
the table.
Instructions and documents are attached to entities in their specific product
application. For example, an instruction for an item is attached in the Master Item
window in Oracle Inventory. Instructions for a standard line operation are attached
in the Standard Line Operation window in Oracle Bills of Material. See:
Attachments, Oracle Applications User’s Guide
Setup
In specific product applications, attach the instructions and documents.
You can attach instructions to the following entities for display in the Flow
Execution Workstation:
■ Item
■ Bills of Material
■ Bills Of Material Component
■ Routing
■ Event
■ Standard Event
■ Sales Order Header
■ Sales Order Line
■ Line Operation
■ Standard Line Operation
See: System Items, Oracle Applications User’s Guide

To set up instruction views in the Flow Execution Workstation:

1. In the Flow Execution Workstation, navigate to the Edit Preferences page for the
parameter preference. See: Setting Your Preferences on page 10-2
2. In the Instruction Frame Height field, you have the option to change the size of
the view. This is a pixel value.
3. In the Instructions boxes, select where to display the instructions and
attachments.
Select attachment source from the Available box—and move to the Selected box.
The order listed in the Selected box, is the order they display on the page. Use
the Arrow tool to change the order. This enables you to specify the priority view
of the attachments. For example, at the line operation level, you can set your
display at that line operation, but also all the documents attached to the events
under that line operation.

To view instructions:
❏ Navigate to the Schedule or Event page.
If only one instruction attachment exists at the schedule or event level, it is
shown in a frame automatically on the page.

If more than one attachment exists, a table displays the list of instructions.
Select a record to navigate to the instruction frame.
Select View All Instructions to display a list of all instructions attached to a
schedule.

Viewing Detail Properties
Viewing Detail Properties

The Detail Properties region displays all the line, schedule, bill of material, and
assembly information about a particular Flow schedule. The information in this
region is derived from the data created when the Flow schedule is created.
Existing descriptive item flexfield data also displays. You can use the System Items
Flexfield for reporting item information. See: System Items, Oracle Inventory User’s
Guide

Viewing Components and Replenishing Kanban Cards
Viewing Components and Replenishing Kanban Cards

You can view and replenish components in the Components region. This region
displays field information for Event Sequence, Item Sequence, Component
Description, Reference, Revision, Unit of Measure, Quantity, Effectivity Date, and
Disable Date. You can access the Replenish Kanban Card page for a specific
component by selecting the Kanban Cards Exist icon. the Replenish Kanban Card
page displays both eligible and ineligible kanban cards defined for a particular
component.
To replenish Kanban cards:

1. Navigate to the Components region, select the component for replenishing by
choosing the Kanban Cards Exist icon.
The Replenish Kanban Cards page displays.
2. In the Cards Available for Replenishment region, select components by
checking the Select box for the card numbers you want to replenish.
3. Choose Replenish.

Integration with Oracle Quality
When you transaction is performed, the record you selected displays in the
Cards Currently Not Available for Replenishment Region.
Integration with Oracle Quality

If collection plans exist for line operations, you can access Oracle Quality to enter
quality data. You can enter results for mandatory collection plans, or optional
collection plans, at specific points on a routing. Line operations cannot be
completed if there are remaining mandatory collections plans. If the collection plan
is mandatory, the Line Operation Completion page displays when you choose
Complete Schedule or Complete Operation. Choose Enter Quality Results to enter
the quality data.
When the collection plan data is entered, and the completion transaction is saved,
the quality data is also saved. See: Entering Quality Results Directly, Oracle Quality
User’s Guide.
Note: The Enter Quality Results button is enabled when Oracle

Quality is enabled for the organization, and a collection plan exists
for the line operation.

Customized Properties Region
Customized Properties Region

You can create a region of new parameters, customized to fit your business needs.
These are fields that do not already exist on the Schedule and Detail Properties
pages, and parameters not delivered with the Flow Execution Workstation.
This region has Name and Value fields. For example, you may want to add a Name
designated as Priority, with a corresponding Value as specified as High Priority.
The custom parameters are added using an applications program interface (API)—
Flow Manufacturing, Execution Utility.
Engineering Change Order Alerts

You can check for engineering change orders (ECOs) related to your assembly.
Changes include adding, changing, or disabling components. The information is
accessed from the Schedule and Event pages. The ECOs that are eligible for display
include:
■ Bill of Material ECOs, not routing ECOs
■ Status is Implemented
■ Components are used at current line operation or event only

This functionality is set up in the Automatic ECO Check field in the Workstation
Preferences page. See: Setting Your Preferences on page 10-2
Eligible ECOs can be flagged for a range of dates. This enables you to have the
correct changes for work as it progresses on the shop floor.For example, if you have
a value of 2 in the ECO Days Prior field, and a value of 3 in and ECO Days After
field—the system considers ECOs in a range of 5 days. This is 2 days before today’s
date, and 3 days after the scheduled completion date.


11
Graphical Kanban Workbench
This chapter describes the functionality in the Graphical Kanban Workbench

including:
■ Overview of the Graphical Kanban Workbench on page 11-2
■ Navigating on the Graphical Kanban Workbench on page 11-2
■ Accessing the Production Region on page 11-5
■ Adding an Item to the Tree on page 11-9
■ Modifying and Creating Pull Sequences on the Graphical Network on
page 11-10
■ Pull Sequence Window on page 11-12
■ Using a Template to Create a Pull Sequence on page 11-14
■ Accessing the Planning Region on page 11-19
■ Viewing Kanban Demands on page 11-25
■ Changing and Viewing Kanban Details on page 11-25
■ Viewing and Changing Summary Pull Sequences on page 11-29
■ Launching a Kanban Plan on page 11-34
■ Updating Production on page 11-34
■ Purging Kanban Cards and Pull Sequences on page 11-37
Graphical Kanban Workbench 11-1

Overview of the Graphical Kanban Workbench
Overview of the Graphical Kanban Workbench

The Graphical Kanban Workbench combines kanban setup, kanban planning, pull
sequence definition, and planning simulation in one interface. The graphical
interface includes the following features:
■ Graphical view the pull sequence network
■ Graphical view the demand pattern for monitoring requirements
■ You can define pull sequence, and have the capability to mass add pull
sequences for items
■ You can add items under locator control and specify point of use, point of
supply, or both as locator sources
■ You can perform simulation replans and updates to production
■ You can view comparison of kanbans by variances in size, or the number of
cards between the two kanban plans being analyzed
See: Overview of Kanban Replenishment, Oracle Inventory User’s Guide.
Navigating on the Graphical Kanban Workbench

The Graphical Kanban Workbench is comprised of two panes. The left pane is the
tree hierarchy. There are two tree tabs located to the left of the tree hierarchy that
allow you to toggle between the Production and Planning views. The View By list
box enables you to change the way you view data in the tree.
The right pane displays the Production or Planning regions in a graphical view of
the kanban network. The right pane contains the data that is associated with the
selected item on the tree. Or it displays the template windows used for creating
templates for your kanban network.
Color Representation
The arrow on the replenishment chain canvas represents the pull sequence between
point of use and a point of supply. One or more cards are generated for a pull
sequence. A color on the arrow is used to easily identify the card status on the pull
sequence. This information is also viewable on the View Kanban Demands and
Compare Kanban Plans windows.The following values are used in the graphical
replenishment network in the right pane:
■ Black: Cards have not been generated for the pull sequence

■ Green: There are cards in the pull sequence that are in the active status
■ Blue: Some cards in this pull sequence are on hold, and none are active
■ Red: All of the cards are canceled
Workbench Toolbar
The right pane canvas displays a toolbar when you are in the Production region. It
contains icons used for creating and modifying your graphical network.
This toolbar contains icons for:

■ Connector: Enables you to create links between entities on the canvas
■ Pointer: Enables you to move existing entities on the canvas
■ Organization: A point of supply that is in another organization
■ Supplier: A point of supply that is a supplier
■ Subinventory: A point of user or point of supply that is a subinventory
■ Production: A point of supply that is a flow line, repetitive line, or discrete
production area
Tools Menu and Pop-up Menus

The Graphical Kanban Workbench enables you to access other manufacturing
functionality. These options are available, depending upon the currently active
window and other conditions, in the Tools menu and pop-up menus.
Tools Menu
Pull Sequence: Accesses the Pull Sequences Summary window to view, update, and
define the source of replenishment for a kanban item, see: Defining Kanban Pull
Sequences, Oracle Inventory User’s Guide.
Kanban Cards: Accesses the Kanban Cards Summary window to view, define, and
update kanban cards, see: Defining Kanban Cards, Oracle Inventory User’s Guide.

Print Kanban Cards - Accesses the request window for printing kanban cards for a
specific item or for all items. see: Printing Kanban Cards, Oracle Inventory User’s
Guide
Generate Kanban Cards: Accesses the Generate Kanban Cards window, see:
Generating Kanban Cards, Oracle Inventory User’s Guide
Forecast/Schedule: Accesses the Item Forecast Entries window where you can review
information for items in a forecast set. See: Defining a Forecast, Oracle Master
Scheduling/MRP and Oracle Supply Chain Planning User’s Guide
Launch Kanban Plan: Accesses the Kanban Planner request window for entering plan
information for kanban calculations. See: Launching a Kanban Plan, on page 11-34,
and Using the Kanban Calculation Program, Oracle Master Scheduling/MRP and
Oracle Supply Chain Planning User’s Guide
Update Production: Accesses the Kanban Details or Update Production Kanbans
window, depending on whether a plan or item is selected on the navigation tree.
These windows enable you to review adjustments to your replenishment chain, and
update the changes in production plans and kanban cards. See: Defining a Forecast,
Oracle Master Scheduling/MRP and Oracle Supply Chain Planning User’s Guide
Pop-up Menus
You can access windows and functions in the pop-up menus by right-clicking on an
icon in the right pane, or a detail in the tree hierarchy.
These options are available, depending upon the currently active window and
where your cursor is located when you right-click in the right pane:
■ Location: Accesses the Location window for the replenishment source for a
kanban location
■ Delete Location: Enables you to remove unconnected locations
■ New: Enables you to add a new items’ replenishment chain, see: Adding an Item
to the Tree, on page 11-9
■ Pull Sequence: Accesses the Pull Sequences Summary window to view, update,
and define the source of replenishment for a kanban item.
■ Kanban Cards: Accesses the Kanban Cards Summary window to view, define,
and update kanban cards.
■ Print Kanban Cards - Accesses the request window for printing kanban cards for
a specific item or for all items.
■ Generate Kanban Cards: Accesses the Generate Kanban Cards window.

Accessing the Production Region
■ Delete Pull Sequence: Enables you to remove the pull sequence; a pull sequence
can only be deleted if the color is black, signifying that there are no cards
associated with it
■ Place Kanban Cards On Hold: Enables you to change the kanban cards to inactive
by changing the status to hold
■ Activate Kanban Cards: Enables you to change the status of kanban cards from
hold back to active
■ Cancel Kanban Cards: Cancels all the cards associated with a pull sequence; items
can be received using the card but not replenished
■ Delete Kanban Cards: Deletes all the kanban cards associated with a pull
sequence, this option is only available if all cards have been canceled indicated
by the color red of the link
■ Forecast/Schedule: Accesses the Item Forecast Entries window where you can
review information for items in a forecast set.
■ Launch Kanban Plan: Accesses the Kanban Planner request window for entering
plan information for kanban calculations.
■ Update Production: Accesses the Kanban Details or Update Production Kanbans
window, depending on whether a plan or item is selected on the navigation
tree. These windows enable you to review adjustments to your replenishment
chain, and update the changes in production plans and kanban cards.

The Production region tree displays all the items that already have pull sequences
defined, and the right pane consists of the detail kanban chain diagram.
This graphical detail view shows the replenishment chain. The replenishment chain
for an item shows all pull sequences that belong to that item.
To view kanban production information on the Graphical Kanban

Workbench:
1. Select Graphical Kanban Workbench on the Flow menu.
2. In the View By list box, select viewing criteria for the kanban data.
Your choices are: Category, Buyer Code, Planner Code, Supplier, Location, Line
Operation, and Process. In the View by Line Operation or Process mode, the
hierarchical tree displays all flow lines and you can expand the tree to see line

operations and processes on the selected line. In the line operation view, an
Unreplenished node at the Line level provides a listing of bill of material
components without defined pull sequences.
3. Select the Production tree tab.

In the initial view, the workbench displays the Template window used for
creating new kanban networks. See: Using a Template to Create a Pull Sequence
on page 11-14
In the All Items by node, you can search for records using the Search Results
node, or view all the records in the All Items node.

4. If you want to find a specific record, or range of records, select the Search
Results node and right-click with your mouse to display the pull-down menu.
Select the Search menu option.
5. Enter search criteria; you can search by item, category, planner, buyer, or any
combination of these values.
6. Choose OK to display the results of your query under the Search Results node.

7. Select a node detail on the tree.

The tree displays all the items that have the pull sequence defined for the
specified plan. The graphical view the pull sequence network displays in the
right pane.
Modifying and Creating Pull Sequences on the Graphical Network on
page 11-10
8. There are four buttons on this window that enable you to navigate to other
kanban windows.
■ Generate Cards: Accesses the Generate Kanban Cards window, see:
Generating Kanban Cards, Oracle Inventory User’s Guide.
■ Cards: Accesses the Kanban Cards Summary window to view, define, and
update kanban cards, see: Defining Kanban Cards, Oracle Inventory User’s
Guide.

Adding an Item to the Tree
■ New--Accesses the Pull Sequence window to fill in fields to create a new

pull sequence, see: Pull Sequence Window on page 11-12
■ Detail: Accesses the Pull Sequence window to view, update, and define this
pull sequence, see: Pull Sequence Window on page 11-12.
Adding an Item to the Tree

The tree hierarchy displays all the items that have a replenishment chain. You can
add new items using the Item window.
To add an item to the replenishment chain:

1. On the tree hierarchy, select the top level node where you want to add another
item.
2. Right click with you mouse on your selection to display the pop-up menu.
3. Select New.
The Item window displays.
4. Enter an item, or select from the list of values.

5. Choose OK
The item appears at the bottom of the list for the top level item, the right canvas
is blank.

Modifying and Creating Pull Sequences on the Graphical Network

Pull Sequences are used to view, update, and define the source of replenishment for
a kanban planned item in a kanban location. You can use the Graphical Kanban
Workbench to create, move, and delete pull sequences.
To create pull sequences for items defined on the tree:

The tree hierarchy only displays items that already have pull sequences
defined. The replenishment chain displays in the right pane.
2. Select a kanban source type icon from the toolbar, and select a location to place
the pull sequence on the right pane canvas See: Workbench Toolbar on
page 11-3
The Location window displays with different fields, depending on your
replenishment source:
■ If you select Organization, select the source organization and subinventory.
If the organization, subinventory, or item is under locator control, you must
also enter a stock locator. See: Assigning a Completion Subinventory and
Locator, Oracle Bills of Material User’s Guide.
■ If you select Supplier, you can optionally select the supplier and supplier
site. If you do not select a supplier, Oracle Purchasing will choose the
supplier based on sourcing rules when it creates a purchase order/blanket
release.

■ If you select Subinventory, select the source subinventory, and stock locator
if applicable.
■ If you select Production, optionally enter the line code.

Pull Sequence Window
3. Select the Connector icon to join the objects together to form a replenishment
chain. Select the location and drag from the point of supply to the point of use.
Connect the objects together—starting with the sub-inventory/locator closest to
your production. When you create the link, the Pull Sequence window appears.
Enter details about the Point of Use and in the Point of Supply. See: Pull
Sequence Window on page 11-12.
4. Save your work.

Use the Pull Sequence window to view, update, and define the source of
replenishment for a kanban item in a kanban location. A pull sequence groups
information for an item defining a kanban location, source information, and
planning parameters. An item can have multiple pull sequences that make up a
replenishment chain. The kanban calculation program determines the optimal
number of kanban cards or size according to the values you enter in the Pull
Sequence window for size, cards, demand, lead time to replenish. See: Defining
Kanban Pull Sequences, Oracle Inventory User’s Guide.
To view and modify pull sequence detail information:

1. Navigate to the Pull Sequence window.
2. Select a value in the Point of Use Subinventory field and a Locator, if applicable.
This is the location where material is used.

3. In the Point of Supply region, indicate the type of pull sequence and the source.
Depending on the source type indicated in the Type field, you must supply
information in the following fields for, Supplier, Site, Organization,
Subinventory, and Line Code. See: Changing and Viewing Kanban Details on
page 11-25
4. The Kanban region is used to select parameters for kanban creation. The
Planning Only box is used if you want the program to perform the kanban
calculations, but you will use a manual system to execute the kanbans.
5. The Auto Request box is used to indicate if this kanban record is flagged for the
Outbound Broadcast Sequencing functionality. See: Overview of Outbound
Broadcast Sequencing on page 9-2
6. The Calculate, Number of Cards, Size, and Minimum Order Qty fields are used
to define kanban card calculations. See: Defining Kanban Pull Sequences, Oracle
Inventory User’s Guide
7. In the Planning region, enter the Lead Time for this location, and optionally
enter Lot Multiplier, and number of Safety Stock Days.

Using a Template to Create a Pull Sequence
8. Choose Generate Cards if you want to create kanban cards for this pull
sequence. See: Generating Kanban Cards, Oracle Inventory User’s Guide.
9. Save your work.

Templates enable you to mass add pull sequences for many items. There are several
options available when creating pull sequences from templates— you can use an
existing template and assign other items, create an entirely new template and assign
items, or you can change the details of an existing template. After creation, the
templates are accessible on the Production region of the Graphical Kanban
Workbench when adding a new pull sequence.
Locator Control
You can add items under locator control when retrieving items for the pull
sequences. When retrieving items you can specify point of use, point of supply, or
both as locator sources in your criteria. Locator records can be retrieved either from
the Bill of Material or from the Pull Sequences.
◗◗ To create pull sequences for items using an existing template:

1. Navigate to the Graphical Kanban Workbench.
2. Select All Items in the Tree Hierarchy.

The right pane displays the Template window. This window displays any
existing template information in a multiple row format including:
Template: The name of the existing template
Point of Use: The subinventory where material is used
Point of Supply—Type and Name: Point of Supply stock areas, from material
stores, a supplier, a production area, or another organization.
3. Select the template you want to use in the multi row table.

4. To add items to this template, choose Assign.

The Template Assignment window displays.
5. Enter Item number, Locator information, and description. See: Defining Kanban
Pull Sequences, Oracle Inventory User’s Guide.
6. To add multiple items, choose Retrieve.
Add Items Criteria window displays. This window restricts your search for
items according to your specifications.
7. Select your search criteria.
You can search by any combination of values including product family, parent
assembly, component, backflush subinventory, or category
In the Item Attributes region, you also have the option to use item attributes in
your search criteria including buyer code, planner code, make or buy status, or
release time fence.

8. Select values in the Locator region if you want to use locator records in the
selection criteria.
Point of Use is where the item is used on the flow line. Your choices are:
■ Bill Of Material
■ Pull Sequence
■ Default—the search uses both bill of material and pull sequence records
after using the other selection criteria entered on the window
Point of Supply is the stock location. You can search for locator records by the
row, rack, bin, project, or task.

9. Choose Find.
The items that met your criteria appear in the Template Assignment window.
You can deselect items by unchecking the check box. Optionally, you can add a
Point of Use Locator or Point of Supply Locator
10. Choose OK to save this retrieval.

The Template window displays again.
◗◗ To create a new template and assign items:

The right pane displays the Template window. This window displays any
existing template information in a multiple row format.
3. Choose New
The Pull Sequence template window displays.
4. Enter a unique value in the Template name field.

Accessing the Planning Region
5. Add information to the fields on this window, see: Pull Sequence Window on
page 11-12
6. Save your work.
7. Assign items to this template, see: Pull Sequence Window on page 11-12.
◗◗ To change the details of an existing template:

3. Select the template in the multi row table, and choose Detail.
The Pull Sequence template window displays with the name of this template in
the Template name field.
You can change any of the fields on this window, see: Pull Sequence Window on
page 11-12.
4. Save your work.

The Planning region is used for kanban planning. The tree hierarchy displays the
kanban plan and all the items that already have pull sequences defined and
demand from this plan. The right pane displays detailed information for the
specified plan. In this region you can view kanban demands, compare kanbans,
perform simulation replans, add, and delete pull sequences or icons on the
graphical network.
To create a new plan:

1. Select the Planning tree tab on Graphical Kanban Workbench on the Flow
menu.
Your choices are: Category, Buyer Code, Planner Code, Supplier, and Location.

3. To create a new plan, select the Item node and right-click to display the popup
menu. Choose New.
The Kanban Plan window displays.
4. Enter a unique value in the Plan Name field, and choose OK.
The plan Detail pane displays.
5. Optionally, enter a description of this plan in the Description field.

6. In the Demand Type field, select the demand source. Your choices are Forecast,
MDS, MPS, or Actual Production.
7. In the Forecast/Schedule field select the name of the specific forecast or
schedule you want to use.
8. Optionally, you can enter a date in the Inactive On field to indicate when this
plan will not be active.
9. Save your work.

To view plan detail information:

1. Select the Planning tree tab on Graphical Kanban Workbench, and select a plan
node on the tree.
The plan Detail pane displays with the specific information for this plan
including plan name, demand type, forecast/schedule, and Inactive On date,
and demand dates. If this plan is completed, a value displays in the Completion
Date field.
2. Choose Launch Plan to access the kanban calculation concurrent program to

determine the number of kanban cards or sizes according to your parameters.
See: Launching a Kanban Plan, on page 11-34, and Using the Kanban
Calculation Program, Oracle Master Scheduling/MRP and Oracle Supply Chain
Planning User’s Guide
3. Choose Calculations to access the Kanban Details window to view the pull
sequences that resulted from the calculations performed in the plan.
4. Choose Demands to access the View Kanban Demand window, see: Viewing
Kanban Demands on page 11-14

5. Choose Comparisons to access the Compare Kanban Plans window, see:

Viewing and Updating Kanban Calculations, Oracle Master Scheduling/MRP
and Oracle Supply Chain Planning User’s Guide
6. Choose Simulation Replan to submit a request to the kanban calculation
program to generate a new simulation plan based on the new values entered.
◗◗ To view plan replenishment information on the Graphical Kanban

Workbench:
1. Select the Planning tree tab.
Your choices are: Category, Buyer Code, Planner Code, Supplier, and Location.
The tree displays all the items that have the planning pull sequence for the
specified plan.

The Replenishment Chain tab displays. This is a graphical view the

replenishment chain for the specified plan selected on the tree. The table
displays the calculated size and the number of cards to each pull sequence. See:
Calculation Formula, Oracle Master Scheduling/MRP and Oracle Supply Chain
Planning User’s Guide.
4. You can modify pull sequence information in this pane by Choosing Detail.
See: Pull Sequence Window on page 11-12.
5. Select the Demand Graph tab.
The graphical view of the demand pattern of a simulation kanban item
displays. This can be used to monitor increases in demand.

6. Select the Pegging tab.

You can use the graphical pegging feature to analyze the impact of changing a
supply or demand order at any level of your bill of material. Pegging traces supply
information for an item to its corresponding end demand details.

Changing and Viewing Kanban Details
Viewing Kanban Demands

The View Kanban Demand window displays the demand distribution for the
specified plan. This window is accessed from the Plan Detail window, displaying
the detail information pertaining to the chosen plan. You can also view this
information in a graphical format in the Demand Graph tab of the Graphical
Kanban Workbench.

The Kanban Detail window enables you to view and update source, quantity and
size, and planning information. You can also change or view pull sequence
information in a graphical format on the Kanban Graphical Workbench.
◗◗ To edit or view kanban detail information

1. Navigate to the Kanban Detail window.
The Kanban Detail window displays, initially in the Source tab view.
2. Select a pull sequence.
You can change subinventory, location, description, and source type.

If the subinventory or item is under locator control, you must also enter a stock
locator.
The replenishment source type for a kanban location can be:

■ Inter-Org is replenished by another another kanban location.
■ Intra-Org is replenished by a kanban location in the same organization,
select the source organization and the subinventory for this source type.
■ Production is replenished by a production line, you can optionally enter the
line code.
■ Supplier is replenished by an external source, you can optionally select the
supplier and supplier site. If you do not select a supplier, Oracle Purchasing
will choose the supplier based on sourcing rules.
See: Overview of Kanban Replenishment, Oracle Inventory User’s Guide.

3. In the Kanban tabbed region, the calculation method displays. You can change
this value.
If you select Do Not Calculate, enter a value in the Size and Number of Cards
fields.
If you select Kanban Size, enter a value in the Number of Cards field and
optionally enter a value in the Minimum Order Qty field.
If you select Number of Cards, enter a value in the Size field, and optionally
enter a value in the Minimum Order Qty field.

4. In the Planning tabbed region, the Lead Time for this location displays.
Optionally enter information in the Allocation Percent, Fixed Lot Multiplier,
and Number Of Safety Stock Days fields.
5. Save your work.

6. There are four buttons on this window that enable you to do the following:
■ Simulation Replan submits a request for kanban replanning.
■ Demand displays the View Kanban Demand window, see: Viewing Kanban
Demands on page 11-14.
■ Update Production updates your production information with this kanban.
■ Select All selects all the details on this window.

Viewing and Changing Summary Pull Sequences

You have the ability to view a summary of all pull sequences of the item numbers
assigned to planners, suppliers, subinventory locations, or buyers. The Pull
Sequence Summary window groups pull sequences and displays the Point of Use,
Point of Supply, and Average Lead Time. This enables you to navigate to windows
to view the number of pull sequences for the selected criteria, make changes or
delete multiple pull sequences simultaneously.
The summary pull sequence view is available both in the Production and the
Planning areas. In the Planning Area you can add and delete mass pull sequences.
However, in the Production area, changes are not allowed to pull sequences that
have released or canceled cards.
To view, delete, or modify summary pull sequence information:

1. Navigate to the Graphical Kanban Workbench, and select viewing criteria in the
View by list box.
3. The pulls sequence summary view is available for are: Buyer Code, Planner
Code, Supplier, Location.

4. Select a record on the hierarchal tree to display the pull sequences on the
graphical pane.
5. Select a pull sequence on the graphical pane, right-click with your mouse to
display the pop-up menu.
The number next to the pull sequence indicates how many records are in the
summary view. The menu choices enable you to view, delete, or modify pull
sequences.

6. Select View Pull Sequences to display all pull sequences the view you selected.
The Pull Sequences window displays.
The Point of Use and Point of Supply Subinventory display. The multi-row
region of the window displays all items used in the pull sequence, their
associated point of use and point of supply subinventory locators, the number
of kanban cards for each item, and the kanban card size.
7. Choose OK to close this window and return to the Graphical Kanban
Workbench.
8. Select Delete Pull Sequences to display the Pull Sequences window.
The multi-row region of the window displays all items used in the pull
sequence, their associated point of use and point of supply subinventory
locators, the number of kanban cards for each item, and the kanban card size.

9. Mark the check box next to the items you want to delete.
10. Choose Delete.
11. Select Modify Pull Sequences.

The Change Pull Sequences window displays. This window has six tabbed
regions including Kanban Size, Number of Cards, Minimum Order, Lead Time,
Lot Multiplier, and Safety Stock. The multi-row region of the window displays
all items used in the pull sequence, the corresponding subinventory, and the
calculation method.

12. For each item you are changing, ensure that the check box next to it is marked.
13. Select the tabbed region needed for the specific changes.
Each tabbed region contains a Current and New field for the corresponding
changed values. For example, if you are viewing the Kanban Size tab, the
number in the Current field is the kanban size. Similarly, if you are in the
Number of Cards tab, the value in the Current field is the number of kanban
cards for this item in the pull sequence.
14. Enter the new value for the modification you are creating.
15. Optionally, in the Changes region, you can enter a global change for all records
on the window by adding a value or percentage the current value. Mark the
Percentage, Value, or Constant radio button.
16. Enter the value you want to add or subject to the current value.
The value you enter adds or subtracts to the current value. If you mark
Percentage, a percent is added. If you mark Value, that number is added. And if
you mark Constant, the value is changed to the new number.

Launching a Kanban Plan
For example, the value in the Current field for Safety Stock is 3 for the first item,
and 2 for the second item. If you mark the Value radio button, and enter
3—when you apply your modification, the first item changes to 6 and the
second item changes to 5.
17. Choose Apply to create your global change on this window.
18. Choose OK to save this record.
Launching a Kanban Plan

The kanban calculation program determines the optimal number of kanban cards or
size according to the values entered in the Pull Sequence window. The calculation
program uses the launch parameters entered including the plan name and demand
date ranges. The kanban calculation program is launched from the Planning region.
After you select a plan in the navigation tree, you can choose Launch Kanban Plan
from the Tools or popup menu. You can also choose Launch Plan from the Plan
Detail window on the workbench.
Note: Kanban calculation does not support independent demand

for components.
See: Using the Kanban Calculation Program, Oracle Master Scheduling/MRP and
Oracle Supply Chain Planning User’s Guide.
Updating Production
Once you have made adjustments to your replenishment chain in the planning
region, you need to update production to reflect the changes in your production
plans and kanban cards.
If you select a plan on the navigation tree, the Kanban Details window is accessed.
You can review kanban data for records in the plan by Source, Kanban, and
Planning detail views.
If you select an item on the navigation tree, the Update Production Kanbans
window is accessed. You can review all items kanban data for a particular plan.

Updating Production
To update production with replenishment information:

1. Navigate to the Graphical Kanban Workbench and select the record you want to
update on the tree,
2. Right click to display the popup menu. Choose Update Production.
You can also select Update Production from the:
■ Tools menu
■ Compare Kanban Plans window
■ Kanban Details window
3. If a plan was selected on the navigation tree, the Find Kanban Details window
displays. Enter search criteria and choose Find to display the Kanban Details
window.
You can review kanban data for records in the plan by Source, Kanban, and
Planning detail views.
See: Changing and Viewing Kanban Details on page 11-25.

Updating Production
4. If an item was selected on the navigation tree, the Update Production Kanbans
window displays.
This window displays eligible records for the plan, and the applicable forecast
or schedule.
5. Select the items you want to update on either the Kanban Details or Update
Production Kanbans window.
6. If you are accessing the Update Production Kanbans window, you have the
option to print new kanban cards after you update production. Enable the
Generate Print Cards box for this print option. See: Printing Kanban Cards,
Oracle Inventory User’s Guide.
7. Choose Update Production.
If there are no conflicting pull sequences, a message displays with the number
of kanbans to be updated.
8. Choose Yes to update production.
The Graphical Kanban Workbench displays.
To resolve pull sequence conflicts:

1. If there is a discrepancy with conflicting pull sequences, the Conflict Resolution
window displays when you choose Update Production on the Kanban Details
or Update Production Kanbans windows.
This window has two regions, New Pull Sequences and Deleted Pull Sequences.
Both regions display fields for Part Number, Description, Point of Use, a
Planning Area and Production Area. The Planning and Production areas
display Point of Supply, Cards, and Size. Conflicts or mismatches with pull
sequences result when:
■ In the New Planning Sequence region, if the Point of Supply is different for
the pull sequence in the Planning Area and Production Area.
■ In the Deleted Pull Sequence region, if the corresponding planning
sequence has an active kanban.
You can verify these conditions in the Replenishment tab detail page.

Purging Kanban Cards and Pull Sequences
2. Enable the Resolve Conflict box to proceed with updating production.

3. Choose Proceed.
A message displays with the number of kanbans to be updated.
4. Choose Yes to update production.
This Production pull sequence is deleted with its corresponding kanban cards,
and the second Production pull sequence is updated.
The Graphical Kanban Workbench displays.

Kanban cards are created based on the information of the corresponding pull
sequence. Over time, unused cards and pull sequences can accumulate in your
database and may affect the performance of the kanban system. You can purge
unused pull sequences and kanban cards by submitting a concurrent program. The

concurrent function purges according to the parameters specified, and creates a

report.
◗◗ To purge kanban cards and pull sequences:

1. Navigate to the Purge Pull Sequences window.
The Parameters window displays.
2. In the Type field, select whether you want a summary or detailed report
generated.
Both formats of the report list the number of cards, the number of pull
sequences deleted, and exception messages. The detailed version also lists
locator, item, and the number of cards deleted per category.
3. In the Item From and To fields, you can select a range of pull sequence item
numbers.
4. In the Subinventory From and To fields, you can select a range of point of use
subinventories for the pull sequences you want to purge.
5. In the Source Type field, select the source type of the pull sequence.
You choices are inter-organization, supplier, intra-organization, and production.

6. Optionally, you can add more search criteria for the source type selected.
This information includes:
■ Flow line for production pull sequences
■ Supplier for supplier pull sequences
■ Organization for inter-organization pull sequences
■ Subinventory for both inter-org and intra-org pull sequences
7. Select a kanban card delete option in the Delete Cards field.
Your choices are Canceled cards only to delete all cancelled kanban cards. Or
Canceled and Active-New cards to delete any card with a status of active and a
supply status of new.
8. Choose OK to display the Purge Pull Sequence request window.
9. Choose Submit to create this request.
All the pull sequences and kanban cards that satisfy the criteria are deleted and
the total number of records purged is displayed on the report
Pull sequences are deleted if:
■ The point of use subinventory and locator defined on the pull sequence
does not exist on any bill of material or WIP Supply location in the
organization item attributes (unreferenced pull sequences). Pull sequences
that are unreferenced are printed as exceptions on the report.
■ The point of use subinventory and locator defined on the pull sequence
does not exist as the point of supply on any other pull sequence.
■ Kanban cards do not exist for the pull sequence.


12
Reports and Processes
This chapter tells you what you need to know about Oracle Flow Manufacturing
Reports and Processes, including:
■ Schedule Report on page 12-2
■ Linearity Report on page 12-4
Reports and Processes 12-1

Schedule Report
Schedule Report
The Schedule Report displays the scheduled production of all assemblies for a line
within a given date range. The purpose of the schedule report is to provide
personnel on the shop floor ready access to the production plan and sequence of
assemblies.
The report includes line name, scheduled completion date, build sequence,
assembly name, UOM, quantity, schedule group, schedule number, order number,
order line, and order requested date.
Setting the Display BOM to Yes explodes the Bills of Material and shows the
following for all components of each assembly: operation sequence, component
number, component UOM, quantity per revision, ECO number, and whether the
component is optional. The Display Optional Items Only parameter is linked with
the Display BOM parameter. Setting the Display Optional Items Only to Yes results
in the report displaying only optional components for the BOM.
Report Submission
Navigate to the Scheduling Reports window. Select Flow Schedule Report.
Report Parameters
From Line
Select the single line or the first line in the range you wish to review. The list of
values displays all active lines in the organization. This is an optional parameter.
To Line
Select the final line in the range to be displayed, if you are requesting data for a
range of lines. The list of values displays all active lines in the organization. Tab
through this field to request date for a single line. This is an optional parameter.
From Date
Choose the start date from which you wish to view line data, if you want a date
other than the default value of the system date. The date must be greater than the
system date.This is a required parameter.
To Date
Choose the end date through which you wish to view line data, if you want a date
other than the default value of the system date. This is a required parameter.

Schedule Report
Schedule Group
Select a specific schedule group to limit the data shown. The default is to show data
for all schedule groups within the line(s) selected. This is an optional parameter.
Display BOM
Enter Yes to include the Bill of Material for the first level of all components for each
assembly in the report. Phantom items are displayed and the Bill of Material will
explode until it reaches a non-phantom item. The default is No.
Display Optional Items Only

This field is active only when Display BOM is set to Yes. Enter Yes to display only
optional items in the BOM.

Linearity Report
Linearity Report
The Linearity Report provides a performance monitoring tool that compares
planned and actual production on a daily basis for the selected date range. The
report displays the planned production rate, the actual production rate, the
variance, and the linearity index for selected lines and, optionally, schedule groups
and assemblies over a given time range.
Variance can be either positive or negative. The linearity index tracks the absolute
value of variance as deviation. The formula for linearity index is:
linearity index = {1 - [total deviations/total planned rate]} * 100
The higher the linearity index, the more closely matched the actual production rate
is to the planned rate.
The Linearity Report can be run with two different sort options and two levels of
detail. The report options include: Linearity Report by Week (Summary), Linearity
Report by Week (Detail), Linearity Report by Line (Summary), and Linearity Report
by Line (Detail). Detail reports include information by assembly in addition to the
information provided on Summary reports. The sort order for Week-based reports
is: week of > line > schedule group. The sort order for Line-based reports is: line >
schedule group > week of.
Summary reports include the following information: date from to date to, week of,
line, schedule group, planned production, actual production, variance, linearity
index, day #, summary for line, summary for week, and weekly total.
Detail reports include the following information: date from to date to, week of, line,
schedule group, assembly, planned production, actual production, variance,
linearity index, day #, summary for schedule group, summary for line, summary for
week, summary for schedule group, and weekly total.
Report Submission
Navigate to the Productivity Reports window. Select Flow Linearity Report.
Report Parameters
Report Option
Select Summary or Detail. If Detail is selected, the report will include information
for individual assemblies. The default value is Summary.

Linearity Report
Sort Option
Select whether the data should be sorted by Week or by Line. The default value is
Week. The sort order for Week-based reports: week of > line > schedule group. The
sort order for Line-based reports: line > schedule group > week of.
From Line
Select the single line or the first line in the range you wish to review. The list of
values displays all active lines in the organization. This is an optional parameter.
To Line
Select the final line in the range to be displayed, if you are requesting data for a
range of lines. The list of values displays all active lines in the organization. This is
an optional parameter.
From Date
Choose the start date from which you wish to view line data, if you want a date
To Date
Choose the end date through which you wish to view line data, if you want a date
Schedule Group
Select a specific schedule group to limit the data shown. The default is to show data
for all schedule groups within the line(s) selected. This is an optional parameter.

Linearity Report

A
Windows and Navigation Paths
This appendix shows the default navigator path for each Oracle Flow
Manufacturing window.
Windows and Navigation Paths A-1

Windows and Navigator Paths

Although your system administrator may have customized your navigator, typical
navigational paths include the following windows and pages.
Oracle Application Description

FLM Oracle Flow Manufacturing
FLMSE Oracle Flow Manufacturing Sequencing and Execution
Window Name Navigation Path

Add Item Routing FLM > Product Sync > Graphical Line Designer > Pop-Up
Menu > New
Alternates FLM > Setup > Bills > Alternates
Attribute Controls FLM > Setup > Items > Attribute Controls
Bill of Materials FLM > Setup > Bills > Bill of Materials Parameters
Parameters
Bills FLM > Bills > Bills
FLM > Reports > Bills
BOM Comparisons FLM > Bills > BOM Comparisons
Category Sets FLM > Setup > Items > Categories > Category Sets
Catalog Groups FLM > Setup > Items > Catalog Groups
Category Accounts FLM > Setup > Items > Categories > Category Accounts
Category Codes FLM > Setup > Items > Categories > Category Codes
ChangeOrganization FLM > Other > ChangeOrganization
Compare Kanban Plans FLM > Kanbans > Graphical Kanban Workbench >
Planning Region > Comparisons
Comparison FLM > Reports > Comparison
Default Category Set FLM > Setup > Items > Categories > Default Category Set
Delete Groups FLM > Delete Groups
Delete Groups FLM > Reports > Delete Groups
Delete Items FLM > Products & Parts > Delete Items
A-2 Oracle Flow Manufacturing User’s Guide


Department FLM > Lines > Department
Department Classes FLM > Setup > Bills > Department Class
Disable Import of FLM > Other > Configurator > Disable Import of Configurator
Configurator Model Model
Documents FLM > Products & Parts > Documents
FLM > Bills > Documents
Event FLM > Product Sync > Graphical Line Designer > Line
Operation or Process tab > Toolbar > Event icon
Feeder Line FLM > Line Scheduling > Feeder Line Sychronization
Sychronization
Flow Routings FLM > Product Synchronization > Flow Routings
Flow Workstation FLM > Production > Flow Workstation
Generate Kanban Cards FLM > Kanbans > Kanban Setup > Generate Kanban Cards
Graphical Kanban FLM > Kanbans > Graphical Kanban Workbench
Workbench
Graphical Line Designer FLM > Product Sync > Graphical Line Designer
Import FLM > Bills > Import
Indented Bills FLM > Bills > Indented Bills
Item FLM > Kanbans > Graphical Kanban Workbench >
Pop-Up Menu > New
Item Types FLM > Setup > Items > Item Types
Item Where Used FLM > Bills > Item Where Used
Kanban Cards FLM > Kanbans > Kanban Setup > Kanban Cards
Kanban Details FLM > Kanbans > Graphical Kanban Workbench >
Planning Region > Calculations
Launch FLM > Kanbans > Kanban Planning > Launch
Line Operation FLM > Product Sync > Graphical Line Designer > Line
Operation tab > Toolbar > Line Operation icon
Lines FLM > Lines > Lines
Location FLM > Kanbans > Graphical Kanban Workbench >
Toolbar > Source Type icon


Locations FLM > Setup > Bills > Locations
Mass Changes FLM > Bills > Mass Changes
Master Items FLM > Products & Parts > Master Items
Mixed Model Map FLM > Product Synchronization > Mixed Model Map
Workbench Workbench
Names FLM > Kanbans > Kanban Planning > Names
Network Connection FLM > Graphical Line Designer > Line Operation or
Process tab > Toolbar > Connection icon
Organization Items FLM > Products & Parts > Organization Items
Populate Configurator FLM > Other > Configurator > Populate Configurator Models
Models
Print Kanban Cards FLM > Kanbans > Kanban Setup > Print Kanban Cards
Process FLM > Graphical Line Designer > Process tab > Toolbar
> Process icon
Product Family FLM > Products & Parts > Product Family
Product Family Members FLM > Products & Parts > Product Family Members
Productivity FLM > Reports > Productivity
Pull Sequence FLM > Kanbans > Kanban Setup > Pull Sequence
FLM > Graphical Kanban Workbench > Replenishment
Chain tab > Detail
Refresh Configurator FLM > Other > Configurator > Refresh Configurator Models
Models
Related Routings FLM > Graphical Line Designer > Pop-Up Menu > New
> Add Item Routing > Related Routings
Requests FLM > Other > Requests
Resource Groups FLM > Setup > Bills > Resource Groups
Resources FLM > Lines > Resources
Routing Details FLM > Graphical Line Designer > Detail
Routing Revisions FLM > Graphical Line Designer > Tools > Routing
Revisions
Routings FLM > Reports > Routings


Scheduling FLM > Reports > Scheduling
Scheduling Rules FLM > Setup > Scheduling Rules
Scheduling Workbench FLM > Line Scheduling > Scheduling Workbench
Setup FLM > Reports > Setup
Standard Events FLM > Product Synchronization > Standard Events
Standard Line Processes FLM > Product Synchronization > Standard Line Processes
Standard Processes FLM > Product Synchronization > Standard Processes
Status Codes FLM > Setup > Items > Status Codes
Switch to Primary FLM > Product Sync > Graphical Line Designer > Tools >
Switch to Primary
Template Assignment FLM > Kanbans > Graphical Kanban Workbench > Assign
> Add Items Criteria
Templates FLM > Setup > Items > Templates
View Kanban Demand FLM > > Kanbans > Graphical Kanban Workbench >
Demand Graph tab
WIP Accounting Classes FLM > Setup > Bills > WIP Accounting Classes
WIP Parameters FLM > Setup > Bills > WIP Parameters
Work Order-less FLM > Production > Work Order-less Completions
Completions
Workbench FLM > Kanbans > Kanban Planning > Workbench
Page Name Navigation Path

Adjust and Submit FLMSE > Create Sequencing Task > Next > Enter Production
Sequencing Task Lines > Next
FLMSE > Create Sequencing Task > Next > Enter Production
Lines > Next > Filter Demands > Next
Assign Production Lines FLMSE > Setup tab >Sequencing Rules > Assign Lines
to Rule
Assign Rule to Production FLMSE > Setup tab > Production Lines > Update > Assign
Lines Rule


Completing Line FLMSE > Workstation tab > Start > Enter Schedule > Line
Operation Operation > Complete Schedule or Complete Line Operation
FLMSE > Workstation tab > Start > Work Queue Criteria >
Start > Work Queue > Complete Schedule or Complete
Operation
Start > Work Queue > Get Schedule > Complete Schedule or
Complete Line Operation
Create Attributes FLMSE > Setup tab > Sequencing Attributes > Create Attribute
Create Constraint for FLMSE > Setup tab > Sequencing Rules > Create Rule > Create
Rule: Enter Details Constraint > Continue
Create Constraint for FLMSE > Setup tab > Sequencing Rules > Create Rule > Create
Rule: Specify Priority and Constraint
Attribute
Create Rule FLMSE > Setup tab > Sequencing Rules > Create Rule
Edit Preferences FLMSE > Setup tab > Workstation Preferences > Edit
Enter Production Lines FLMSE > Create Sequencing Task > Next
Enter Sequencing Task FLMSE > Create Sequencing Task
Parameters
Enter Schedule FLMSE > Workstation tab > Start
Event FLMSE > Workstation tab > Start > Enter Schedule > Get Event
Start > Work Queue > Get Event
Filter Demands FLMSE > Create Sequencing Task > Next > Enter Production
Lines > Next
Line Operation FLMSE > Workstation tab > Start > Enter Schedule > Get
Schedule
Start > Work Queue > Get Schedule
Move Demands Adjust and Submit Sequencing Task > Move
Parameters FLMSE > Workstation tab
Production Lines FLMSE > Setup tab > Production Lines
Rule detail FLMSE > Setup tab > Sequencing Rules > rule Name
Select Preferences FLMSE > Setup tab > Workstation Preferences


Sequencing Attributes FLMSE > Setup tab > Sequencing Attributes
Sequencing Rules FLMSE > Setup tab > Sequencing Rules
Sequencing Tasks FLMSE > Sequencing Tasks
Split Demands Adjust and Submit Sequencing Task > Split
Task Detail FLMSE > Sequencing Tasks > Sequencing Task Name Task
Summary > View
Task Summary FLMSE > Sequencing Tasks > Sequencing Task Name
Update Constraint for FLMSE > Setup tab > Sequencing Rules > Create Rule >
Rule: Specify Priority and Update
Attributes
Update Demands Adjust and Submit Sequencing Task > Update
Update Line Task FLMSE > Create Sequencing Task > Next > Enter Production
Parameters Lines > Next > Adjust and Submit Sequencing Task > Update
FLMSE > Create Sequencing Task > Next > Enter Production
Lines > Next > Filter Demands > Next Adjust and Submit
Sequencing Task > Update
Update Production Line FLMSE > Setup tab > Production Lines > Update
Work Queue Criteria FLMSE > Workstation tab > Start
Work Queue FLMSE > Workstation tab > Start > Work Queue Criteria >
Start


B
Line Scheduling Calculation Examples
This appendix contains examples of the calculations used to create flow schedules
in the Line Scheduling Workbench. These examples include:
Scheduling Calculations and Examples on page B-2
Roll Flow Schedules on page B-4
Tolerance Fences on page B-4
Feeder Line Synchronization Calculations on page B-5
Line Scheduling Calculation Examples B-1

Scheduling Calculations and Examples

Scheduling rules use the following routines for calculations:
■ Sequence is determined by the criteria in the rule.
■ The first flow schedule created is slated to the first available date in the
scheduling horizon.
■ This process of attaining the line rate for each day continues until the end of the
scheduling horizon.
Note: For No Level Load and Level Daily Rate algorithms,

unscheduled orders generated from planned orders have quantities
initially changed by order modifiers, if they exist. Order modifiers
(fixed order quantity, minimum order quantity and maximum
order quantity) are used to limit lot size.
Note: If items have the rounding attribute set to yes, flow

schedule quantities are non-fractional, that is, quantities are
rounded to whole numbers.
No Level Loading Algorithm

If you choose a scheduling rule that has no level loading, the level daily rate and the
mix model algorithms are not used in scheduling the sales orders. The criteria
defined in the scheduling rule is used to prioritize and sequence the sales orders.
Orders are scheduled on the line with capacity constraint considerations. After
using the criteria in the scheduling rule to sequence the sales orders, scheduling
begins with the first sales order in the sequence. The scheduling process searches
for available capacity beginning with the first date of the scheduling date range. If
the entire order quantity cannot be scheduled on a date, the remaining quantity is
scheduled on subsequent days where capacity is available.
Level Daily Rate Algorithm

If you choose a scheduling rule that uses level daily rate for leveling, the demand
ratio of the item is used to calculate the quantity scheduled. The demand ratio of an
item equals the total demand of the item divided by the grand total demand.
B- Oracle Flow Manufacturing User’s Guide

The quantity scheduled for an item on a particular day is determined by the

available capacity of the line on the day and the demand ratio of the item. The
calculations performed each day are as follows:
■ The total demand for each item is calculated from all unscheduled sales orders.
■ The grand total demand is calculated for all items.
The demand ratio is calculated. For each day in the scheduling horizon, the
production quantity for each item is calculated by multiplying the available
capacity on the line by the demand ratio of the item.
Scheduling using level daily rate attempts to schedule, for each day, each item at a
rate in regard to the demand ratio of the item. The criteria selected is used to
prioritize schedules; scheduling continues until capacity is reached or until all
demand is scheduled.
Mixed Model Algorithm

In scheduling rules using a mixed model algorithm for leveling, sales orders are
scheduled with the goal of achieving a balanced production mix across all items. In
this case, flow schedules are created with unit quantity and scheduled in order to
create the total demand of each item.
The key difference between the mixed model algorithm and the level daily rate is
that the calculation is at the unit level, whereas in level daily rate the calculation is
at the daily level. There are two key steps in the process of establishing the
production pattern:
■ The total demand for each item is calculated from unscheduled sales orders.
■ The production pattern is established using the total demand of each item and
spreading out the demand to show the demand mix of all items.
The criteria defined in the scheduling rule prioritizes and sequences the sales
orders, and the orders are scheduled on the line based on the established
production pattern. During the scheduling process, the earliest available capacity is
used to schedule the items on the line. Daily capacity constraints are used in the
calculation.

Roll Flow Schedules
Roll Flow Schedules

Rolling flow schedules forward adds undercompletion quantities to the schedule,
and subtracts overcompletions quantities from the schedule – past planned
quantities are not reduced or increased. A report is generated from this process
showing the effect of moving flow schedule quantities to future dates. Select your
flow schedules by date ranges, lines, or categories. Choose Close All Past Due
Schedules, Roll with Details, or Spread Evenly Without Details.
Tolerance Fences
Tolerance fences indicate how much flexible capacity the line has available. You
enter a value in the Day in Advance field on the Tolerance Fence window in Oracle
Work in Process. This value indicates the number of days of notice needed before
increasing the line capacity by the tolerance percentage. The Days in Advance value
should be greater than or equal to the fixed lead time value.
This feature is activated by checking the Flex Tolerance check box on the Line
Scheduling Workbench.
Scheduling with tolerance fences begins after the last day indicated from the Days
in Advance value. For example, if Days in Advance is 5, scheduling at the new
capacity begins on the sixth day. Other factors in the calculations include:
■ Capacity is added incrementally. The standard rate is used first to schedule all
items. If the items cannot be scheduled by using the standard rate, the program
considers the first tolerance fence and attempts to schedule within that capacity.
If there is still not enough capacity, the second tolerance fence is considered,
and so on.
■ When line scheduling start and stop times are within the line definition start
and stop times, the extra capacity provided by the tolerance fence is prorated
based on the portion of the day being scheduled. For example-capacity is 100
for a line, the tolerance fence percentage is 10 percent, and the standard line
definition is from 7:00 to 15:00 hours (8 hours). If the scheduled start and stop
times are 7:00 to 11:00 hours (4 hours), the flexible tolerance fence capacity is 5
percent.:
4 divided by 8 = .5
.5 multiplied by 10 = 5
■ Decimal calculation results for the new line capacity are rounded up.

Feeder Line Synchronization Calculations
■ All schedules created within the tolerance fence, but over the standard running
line capacity, are scheduled to complete at the stop time of the line.
Tolerance fences provide temporary increases to capacity above the normal
operating rate to handle rises in orders. If you want to permanently increase the
standard operating rate to correspond with a change in demand–update the line
rate in the line design.
Note: The lead time of the item being scheduled is not part of the
Days in Advance total. You must perform the scheduling operation
sufficiently in advance to accommodate the lead time.
Schedule Completion Time

When the line scheduling start and stop times are outside the line definition start
and stop times, the calculations are as follows:
■ The first schedule completion time is the sum of the line start time and quantity
divided by the line rate.
■ The other schedule completion times are the sum of the previous completion
times and quantity divided by the line rate.
■ The last schedule completion time ends at the end time of the line.
When the line scheduling with start and stop times are within the line definition
start and stop times:
■ The first schedule completes at scheduling start time
■ The other schedule completion times are the sum of the previous completion
time and quantity divided by the line rate.
■ The last schedule completion time ends at the scheduling end time
Start times = [completion time - (fixed lead time + (quantity-1) x variable
lead time)]

The feeder line synchronization program calculates the date and time when the
subassembly is delivered to the particular line operation. This date is then used as
the completion date for the subassembly line. To calculate this time, the program
uses the following formula:

The values are defined as follows:

■ S is the subassembly completion time.
■ P is the parent item completion time.
■ fn is he operation time rounded up to the closest multiple of takt. Summation is
done by following the routing network primary paths from the point of
consumption to the consuming operation.
takt = parent line takt = 1/maximum hourly rate from parent line definition
Example: Feeder Line Synchronization

The following graphic illustrates an example of a flow line producing pumps. On
the main line is the final pump assembly. The subassembly line produces pump
housings and feeds the line at Operation 5.

The values are defined as follows:

■ P is the completion time of the final pump assembly as scheduled
■ S is when the subassembly, the pump housing, is consumed at Operation 5
■ T is the takt time, 30 minutes
When you schedule the parent line, schedules are created with P as the completion
time. The completion time of the subassembly is shown in the following calculation


C
Mixed Model Map
This chapter provides information on how to use the mixed model map to design a
balanced production. Topics include:
■ Overview of Mixed Model Map on page C-2
■ Entering Mixed Model Map Parameters on page C-2
■ Generating a Mixed Model Map on page C-4
■ Saving a Baseline on page C-7
■ Querying a Saved Baseline on page C-8
■ Placing a Mixed Model Map on the Navigator on page C-9
■ Mixed Model Map Calculations on page C-10
Mixed Model Map C-1

Overview of Mixed Model Map
Overview of Mixed Model Map

Line design is the process of defining a production line, the products that you make
on the line, the operations that you perform to make these products, and the
resources and materials consumed at each step. The mixed model map helps you to
create and monitor your line design. To balance a line against a specified demand,
you will use the mixed model map which calculates the following at each process or
line operation:
■ Process volume
■ Machine, labor, and total times
■ Machine, labor, and total weighted times
■ Machine and labor requirements
■ Line, Process, and Operational Takt Time
■ In-process kanban (IPK) requirements
In the Mixed Model Map the resource requirements are displayed in the summary
table. You can also view details of the resources in the Resource Detail window.
See Also
Entering Mixed Model Map Parameters on page C-2
Saving a Baseline on page C-7
Placing a Mixed Model Map on the Navigator on page C-9
Entering Mixed Model Map Parameters

Prerequisites
❏ You must create at least one line before you can create a mixed model map.
❏ You must have at least one flow routing for that line enabled for the Mixed
Model Map. All enabled routings must have operation times and yields
calculated or entered manually.
❏ You must have a demand schedule defined for the products on the line
(forecast, MPS, MDS, flow schedule)
C-2 Oracle Flow Manufacturing User’s Guide

Entering Mixed Model Map Parameters
To enter mixed model map parameters

1. Navigate to the Mixed Model Map window.
2. In the Select region, select the line for generating a mixed model map.
3. Optionally, enter a family name if you want to restrict the display to a specific
Product Family.
4. In the Demand Type field, select a value representing the source of this demand.
The Demand Name displays for forecasted values. Your choices are:
■ Forecast—an estimate of future demand
■ MDS—master demand schedule, the anticipated forecasted ship schedule
■ MPS—master production schedule, the anticipated forecasted build
schedule
■ Actual Production—demand generated from existing sales
5. Select start and end dates to calculate the number of demand days.
The default is the beginning of the demand period.
Mixed Model Map C-3

Generating a Mixed Model Map
6. In the Demand Days field, the value is calculated by the difference in the date
fields entered. Or the value can originate from the forecasted demand.
7. Enter the hours per day that you are working.
8. Optionally, enter a boost percentage to increase or decrease your demand.
9. In the Display Option region, choose options for viewing the generated mixed
model map.You can balance the line by line operation or process. Select Line
Operation or Process to determine what displays on the matrix.
10. Select the Sort Order; choices are Display Sequence or Code.
11. In the Time field, select what machine or labor time values are used for the
calculation.
■ Rolled-Up Time uses the value derived from the Usage field on the Event
Resources window.
■ User Entered is the value entered on the Routings window, in the Operation
Times tab, in the User Labor Time or User machine time fields.
12. Select the calculate for In Process Kanban Value. Your choices are either the
entire process, or for each individual machine.
The number of machines is specified at the department associated with the
process.
13. Select a unit of measurement for the time values displayed in the mixed model
map.

To generate a mixed model map
Enter Mixed Model Map parameters. See: Entering Mixed Model Map
Parameters on page C-2
2. Choose Generate.

The Mixed Model Map window displays the takt time hours available for the
line.
In the first tabbed region in the upper part of the window, the information is
displayed by elapsed time, machine time, labor time, and process volume.
In the second tabbed region in the lower part of the window, you can view
baseline data.
■ The Summary tab displays machine and labor values that are needed and
assigned.
■ The Baseline Variance tab displays a bar graph, you can choose to view
variance by machines needed, labor needed, or in process kanbans needed.
The baseline value for each process is shown in yellow as a column. If more
resources (machines, labor, or in process kanbans) are needed than the
current baseline value, the variance appears in red and a positive variance
value is shown above the column in red. If fewer resources are needed than
the current baseline value, the variance appears in blue and a negative
variance value is shown above the column in blue.
Mixed Model Map C-5

■ The Baseline tab displays the required machine, labor, and in process
kanban values.
3. You can select a record on the mixed model map, and access details of that
record. You can either view, define, or query in windows through the following
options on the Tools menu:
■ Standard Processes—Standard Processes window
■ Standard Line Operations—Standard Line Operations window
■ Flow Routings—Routings window
■ Forecast Entries—Item Forecast Entries window
■ Master Demand Schedule Entries—Item Master Demand Schedule Entries
window
■ Master Production Schedule Entries—Item Master Production Schedule
Entries window
■ Kanban Planner Workbench—Kanban Workbench window
■ View Baseline—View Baseline window
■ Save as Baseline—Saves this mixed model map as the baseline calculation
■ Resource Details—Resource Details window
Resource Details Window

In the Mixed Model Map the resource requirements are displayed in the summary
table. You can view resource, activity, line operation, resource type, and usage in the
Resource Detail window. This enables you to make decisions on how best to move
and adjust the resources. by displaying machine and labor details.
To view resource details in the mixed model map:

1. Select Resource Details from the Tools menu.
2. Use the Find Resource Details region to choose selection criteria.
You can view all resources by choosing Find. Or you can filter your selection by
selecting values, or any combination, in the Resource, Line Operation, Activity,
or Resource Type fields—and then choose Find.

Saving a Baseline
The window displays details by Resource, Activity, Line Operation and

Resource Type. The the total usage calculated for all resources that meet the
selection criteria displays in the Resources Needed field. This value is the
weighted average usage of the corresponding resource across all assembly
items on the line, and all events— per the demand.
3. Choose OK to close the window and return to the Mixed Model Map.
4. Choose Export save this generated information in a file a file in another
location.
Saving a Baseline
You can save a Mixed Model Map as a baseline on a certain line and optionally for a
certain family with a specific demand. Only one baseline can be saved for each
product family and line combination. You compare any other calculations for this
Family/Line/Forecast to this baseline.
Mixed Model Map C-7

Querying a Saved Baseline
To save a baseline:
❏ After you have generated a mixed model map, choose Save as Baseline from the
Tools menu.
In the Saved Baseline window you can select the Find button to view all of the
saved baselines
.
Attention: If you have a previously saved baseline for this family

and line, it will be replaced when you save it again.
Querying a Saved Baseline

You can bring up a saved baseline to compare calculations with different variables
or over a period of time. The View BaseLine window displays the calculated
machine, labor, and in process kanbans values you saved from the Mixed Model
Map window.
To query a saved baseline:

2. Select View Baseline from the Tools menu to display the View Baseline window.
The window displays the parameters used to generate the map. You can view
the machine, labor, and in process kanbans by both processes and line
operations.
3. Close this window to return to the Mixed Model Map window, or choose Delete
to delete this saved record.

Placing a Mixed Model Map on the Navigator
Note: To view all saved maps, navigate to the Line field and select
the query button.
Placing a Mixed Model Map on the Navigator

You can save a baseline to your Navigator desktop for easy access.
Prerequisites
You must create a Mixed Model Map before you can place it on the navigator. See:
Entering Mixed Model Map Parameters on page C-2, and Generating a Mixed
Model Map on page C-4.
To place a Mixed Model Map on the navigator

1. Generate a Mixed Model Map or query the baseline you would like to save to
the Navigator.
2. Choose Place on Navigator from the file menu.
Mixed Model Map C-9

Mixed Model Map Calculations
Note: Place on Navigator option is only available when you are in

the Mixed Model Map matrix window.

The mixed model map enables you to design and monitor each part of the line
design process. The mixed model map bases calculations on the date range entered
in the Mixed Model Map window if this date range falls within the forecast date
range. Otherwise the forecast date range will be used.
Line Takt Time

Line Takt time is calculated as follows:
hours per day * time conversion factor * number if demand days
divided by total demand * (1 +boost percent)
Hint: Once your line is balanced, return to the organization item

master and update the variable lead time to equal your Line Takt
Time. The Total Product Cycle time (which is displayed on the
routing for each item) should be entered in the fixed lead time field
on the item master attributes.
Process Volume
Process volume is calculated as follows:
total demand * average net planning percent * (1 + boost percent)
divided by average reverse cumulative yield
T
Note: A process volume is calculated for a product and a process

(or line operation). If the reverse cumulative yield is 0, the system
will assume it is 1.
Machine Weighted Time

Machine weighted time is calculated as follows:
sum of (process volume * machine time)
divided by the sum of process volume

Labor Weighted Time

Labor weighted time is calculated as follows:
sum of (process volume * labor time)
divided by sum of process volume
Elapsed Weighted Time

Elapsed weighted time is calculated as follows:
sum of (process volume * elapsed time)
divided by the sum of process volume
Note: Machine, labor, and elapsed weighted times are calculated

by process (or line operation). For example, if your mixed model
map displays five processes, then the mixed model map will
calculate five machine weighted times, one for each process.
Machines Needed
Machines needed is calculated as follows:
machine weighted time
divided by operation takt time
Note: The mixed model map calculates the number of machines

needed by process or line operation.
Machines Assigned
Machines assigned is the total number of machine resources in the department(s)
that the events are assigned to.
For example: OP10 is assigned to DEPT1, and there are two events underneath it.
One event uses machine MCH1 for 0.25 hours and is assigned to DEPT1. The other
event uses MCH2 for 0.1 hours and is assigned to DEPT2.
The program will look at DEPT1, note the total MCH1 resources assigned. It then
goes to DEPT2, and notes the total MCH2 resources assigned. These two numbers
are added together and displayed as machines assigned.
Mixed Model Map C-11

Note: The number of resources assigned is the TOTAL available in

the department(s), not the total available for that operation. IE - If
you use the same machine resource at multiple events in the same
line, or in multiple lines, the machines assigned will be overstated
for each occurrence of the resource. The only way to avoid this is to
assign a department to each operation/process and all its events.
Labor Needed
Labor needed is calculated as follows:
labor weighted time
divided by operation takt time
Note: The mixed model map calculates labor needed by process

or line operation.
Labor Assigned
This is the total number of labor resource units in the department(s) that the events
are assigned to. It is calculated in the same manner as Machines Assigned.
Note: The number of resources assigned is the TOTAL available

in the department(s), not the total available for that operation. IE -
If you use the same labor resource at multiple events in the same
line, or in multiple lines, the labor assigned will be overstated for
each occurrence of the resource. The way to avoid this is to assign a
department to each operation/process and all its events.
In Process Kanbans (IPKs) Needed

IPKs Needed is calculated as follows:
(elapsed weighted time - line takt time) * hours/day * time conversion factor
divided by elapsed weighted time * line takt time
Note: The mixed model map calculates the number of IPKs

needed by process (or line operation).

In Process Kanbans Needed by Machine

In Process Kanbans needed by machine is calculated as follows:
in process kanbans needed
divided by the number of machines
Note: Operational takt time is calculated for a process or line

operation, unlike the line takt time which is calculated for the entire
line.
Operation Takt Time

Operation Takt Time is calculated using the following formula:
number of days * hours per day * time conversion factor
divided by the sum of process volumes
Takt Time for Assigned

Takt time for assigned is the time per unit that each operation will achieve given the
number of resources assigned. (Also called the Operational Cycle Time)
Takt Time for Assigned is calculated using the following formula:
Machine Weighted Time / Machines Assigned
If machines assigned is equal to 0, then takt time for assigned is 0.
Note: This number is relevant only if you assign a department to

each operation or process and all of its events.
Mixed Model Map C-13


D
Mixed Model Map Workbench Calculations
Mixed Model Map Workbench Calculations D-1


Mixed Model Map Workbench uses the following calculations:
Calculate
The Calculate function on the Mixed Model Map Workbench performs calculations
using parameters specified for a plan. Calculate options include:
❏ No IPK—resource requirements are calculated using the IPK value as zero on
the line operation.
IPK Needed = 0
Resource Needed per operation
= Weighted Resource Usage
divided by Operation TAKT for the operation
❏ Based on one resource—the IPK needed on the line operation is calculated
assuming one resource at each operation.
Resource Needed per operation = 1
IPK Needed per operation
= Maximum Resources (Weighted Resource Usage per operation)
subtracted by Operation TAKT
divided by Maximum Resource (Weighted Resource Usage per operation)
multiplied by Working Hours Per Day of the line divided by Operation
TAKT for the operation
❏ Based on Assigned IPK—resources are calculated using the Assigned IPK at the
line operation.
IPK Needed for the operation = IPK assigned or the operation
Resource Needed at each line operation
= Working Hours Per Day for the line
subtracted from the IPK Assigned for the operation
multiplied by Weighted Resource Usage
divided by the Working Hours per Day for the line
D-2 Oracle Flow Manufacturing User’s Guide

❏ Based on Assigned resource—the IPK Needed on the line operation is

calculated using all the Assigned resources.
IPK Needed for the operation
= Maximum resource (Weighted Resource Usage divided by Resource
Assigned
subtracted by Operation TAKT
divided by Maximum Resource (Weighed Resource Usage divided by
Resource Assigned)
See: Viewing, Creating, and Updating Plans on page 5-4
Line TAKT:
Rate the line produces one item to fulfill demands:
Working Hours Per Day (per line)
divided by Average Daily Demand for the item.
Operation TAKT
Rate the operation produces one item to fulfill operation demands. A single line can
be used to manufacture multiple items, different items can have different routings,
and some operations might be unique for a particular item.
Operation TAKT
= Working Hours per day for the line
divided by the item Process Volume

Process Volume
The number of items an operation produces in manufacturing day. A single
operation can be used to manufacture multiple items, different items can use
different routings, and some operations might be unique for a particular item.
Process Volume is not effected by Assigned Resources and IPK.
Process volume
= Average Daily Demand for the item
multiplied by Net Planning Percent for the operation
divided by Reverse Cumulative Yield for the operation
Machine, Labor, Elapsed, Weighted Time

This includes:
■ Total Machine Resources usage time in an operation
■ Total Labor Resources usage time in an operation
■ Total Machine and Labor Resources usage time in an operation
■ Weighted Time is the weighted average usage time across all items produced in
a line.
Machine, Labor, Elapsed, and Weighted Time are not effected by Assigned
Resources, only usages are considered.
Weighted Time per operation
= sum of item manufacturing time
multiplied by Process Volume per item, per operation
divided by the sum of all items Process Volume per item, per operation
Usage, IPK, Assigned

For example:
Usage is 1
Assigned is 0.5, and the calculation is based on Assigned Resources
IPK is used to fulfill the required resource
The outputs will then be used by the next operation to keep the line flowing.

If the IPK is 20, 20 extra components are needed at the end of the resource per day,
to keep the line flowing
See: In Process Kanban Assignment on page 5-22
Operation TAKT As Assigned

Example 1:
Operation TAKT is 15 minutes
Usage is 1, Assigned is 2
Resource TAKT is 7.5 minutes
The work can be completed 2 times faster, that is—15 divided by 2 = 7.5 minutes
Example 2:
If Operation TAKT is 15 minutes
Usage is 2, Assigned is 3
Resource TAKT is 10 minutes.
The work can be finished 3/2 times faster, that is—15 divided by (3/2) = 10 minutes
Line TAKT As Assigned

The ratio of Line TAKT As Assigned, and Line TAKT, is the maximum ratio of the
Operation TAKT As Assigned and Operation TAKT in the line.
■ When Operation TAKT As Assigned is greater than Operation TAKT, the
current setup results in slower time to complete the operation.
■ When Operation TAKT As Assigned is less than Operation TAKT, the current
setup results in faster time to complete operation.
Color Representation on the Mixed Model Map Workbench
Lines
Line TAKT As Assigned
■ Red—Resource over-capacity or IPK over-capacity is greater than 0
■ Yellow—Line TAKT As Assigned is greater than Line TAKT
Operations:
Operation, Operation TAKT As Assigned

■ Red—Resource over-capacity or IPK over-capacity is greater than 0

■ Yellow—Operation TAKT As Assigned is greater than Operation TAKT
Operation Detail
Resource, Usage, Needed, IPK Needed
■ Red—IPK Needed is greater than IPK Assigned
■ Yellow—IPK Needed is greater than 0, and Maximum Resource Needed or
Assigned is less than Usage
Resources
Resource, Needed, Relocation Needed
■ Red—Resource Needed is greater than Resource Assigned
■ Yellow—Relocation Needed = Yes
Resource Detail
Line, Operation, Resource Needed, IPK Needed
■ Red—Resource Needed is greater than Resource Assigned
■ Red—IPK Needed is greater than IPK Assigned
Resource Assignments
Department, Unit, Total Unit
■ Red—Unit is less than Assigned
■ Red—Total Units is greater than Total Assigned
Percentage Needed
The percentage difference between Assigned and Needed based on the Needed
value:
Assigned subtracted by Needed
divided by Needed
multiplied by 100
■ Green—resource is over-assigned
■ Red—resource is under-assigned

Percentage Assigned
The percentage difference between Needed and Assigned based on the Assigned
value:
Needed subtracted by Assigned
divided by Assigned
multiplied by 100
■ Green—resource is over-assigned
■ Red—resource is under-assigned
Percentage number 999 signifies a value is zero or null.
Absolute Value
Needed (blue) and Assigned (green) values are displayed next to each other for
comparison.


Glossary
Allocation Percent
See kanban allocation percent.
Areas
Areas represent either a section of the plant floor or an entire plant facility. You can
use inventory organizations to define areas.
assemble-to-order (ATO)
An environment where you open a final assembly order to assemble items that
customers order. Assemble-to-order is also an item attribute that you can apply to
standard, model, and option class items.
assembly scrap
A process which allows you to scrap both scheduled and unscheduled flow
assemblies from any flow operation. Operation Pull, Assembly Pull, and Assembly
Push components, their associated costs, and all labor and machine resources used
at all events prior to the scrap line operation are automatically backflushed.
ATO
See assemble-to-order.
1
C
Calculation Formula
One of the most important tasks of a Kanban planning system is determining the
optimal number of Kanban cards. The Kanban planning software takes care of this
calculation provided you enter correct values for Kanban size, average daily
demand for the Kanban item, and the lead time to replenish one Kanban. We
provide a package that you can use to customize the calculation. See the Oracle
Manufacturing, Distribution, Sales and Service Open Interfaces Manual. By default,
the standard calculation is: (C – 1) * S = D * (L + SSD) where: C is the number of
Kanban cards S is the Kanban size D is the average daily demand L is the lead time
(in days) to replenish one Kanban. If you think through the Kanban process, you
will see why this formula works best when the demand for the Kanban item is
steady. In addition to this basic formula, when the calculation program calculates
Kanban size, it takes into account the values for the following order modifiers
(specified in the pull sequence), in the following order: Supply Days, Minimum
Order Quantity, and Lot Multiplier. For example, suppose you have specified the
Minimum Order Quantity for a particular item to be 50. You want the formula to
calculate the Kanban size (S), so you enter values for S, D, and L. Even
though—strictly based on the values you enter for C, D, and L—the formula should
yield 40, the actual Kanban size will be 50 because of your order modifier, assuming
the Lot Multiplier is a factor of 50.
Note: The program uses order modifiers only when calculating the Kanban size. If
you specify the Kanban size and want the program to calculate the number of
Kanban cards, the program does not use order modifiers.
Card Status
See kanban card status
CFM
Continuous Flow Manufacturing.
CFM Schedule
Work Order-less Schedule. In this document this would mean both the Scheduled
and Unscheduled Flow Schedules.
cumulative yield
Product of the yields at each operation, process, or event on a flow line.
2
D
Down-time
Time when a resource is scheduled for operation but is not producing for reasons
such as maintenance, repair, or setup.
Dual Card Kanban

A demand pull signal that uses a “move” and “produce” communication method.
Generally, “move” cards are collected and when the “produce” lot size is reached,
the “produce” card is used to create the replenishment. This procedure is generally
used when a minimum order quantity is required as a result of long set up times or
economic order cost.
efficiency
A productivity measure that focuses on actual performance against a standard.
Expressed in a percentage figure, it is calculated by dividing actual resource time
charged to a task by the standard resource requirements for the same task.
elapsed time
The clock time between start and completion. For example, if the build time of a
resource is 10 hours, but you only schedule 5 hours of work a day, the elapsed time
is 29 hours.
events
An event is an identifiable point in time among a set of related activities.
Graphically, an event can be represented by two approaches: (1) in activity-on-node
networks, it is represented by a node; (2) in activity-on-arc networks, the event is
represented by the arc. In flow manufacturing, events are the lowest level of
activities in a flow routing. Resources are assigned to events. Events can be grouped
into processes and operations.
Feeder Line
A production line designed to feed sub-assemblies to a line producing higher level
assemblies.
3
A concurrent process that allows you to synchronize sub-assembly flow schedules
sequence with the parent assembly line flow schedule sequence.
first unit completion date

The date and time you plan to complete production of the first assembly on a
repetitive schedule. This date equals the first unit start date plus the lead time.
first unit start date

The date and time you plan to begin production of the first assembly on a repetitive
schedule. This date equates to the start of your lead time.
flexible tolerance fences

Used to represent the flexibility of supplier capacity. Shown as the percent increase
or decrease over daily production rate available from a given supplier for a set
amount of time.
flow line
The physical location where you manufacture a flow assembly, usually associated
with a routing(s). You can build many different assemblies on the same line at the
same time. Also known as assembly line or flow shop.
flow manufacturing
Manufacturing philosophy utilizing production lines and schedules instead of work
orders to drive production. Mixed models are grouped into families and produced
on lines balanced to the takt time.
flow routing
A sequence of manufacturing events that you perform to manufacture an assembly.
In the flow routing, these events can be grouped in processes and balanced
operations. A routing consists of an item, a series of events, processes and/or
operations, a operation sequences, operation effective dates, and a flow routing
network. You can also perform operation time, yield and total product cycle time
calculations in the flow routing.
Flow Routings and Sequence of Events

Flow Routings define the production process of an assembly on the production line.
You can use Flow Routings to define the processes and the sequence of events
within each process. You can specify the setup, run, and move times for each event
by associating the required resources.
4
flow routing network
A process-map of your processes and operations where you specify the primary
path, alternate paths, feeder lines and rework loops within your flow line.
flow schedule
A schedule for your flow line that represents the volume and mix of products to be
produced. Scheduling can be done based on customer orders and scheduling rules,
with an objective of matching the customer orders as closely as possible while
establishing an achievable pace and consistent flow of products through the flow
line. Schedules DO NOT produce work orders.
flow workstation
The assigned location on a flow line where a worker performs the job. It could be a
machine or a workbench.
kanban
A method of Just-in-Time production that uses standard containers or lot sizes with
a single card attached to each. It is a pull system in which work centers signal with a
card that they wish to withdraw parts from feeding operations or suppliers. The
Japanese word kanban, loosely translated, means card, billboard, or sign.
kanban allocation percent

Percent of independent demand for the kanban item that is to be supplied from a
given pull sequence.
kanban card
The visual replenishment signal. It corresponds to a kanban bin. Replenishable
kanban cards are based on pull sequences; non-replenishable cards can be created
manually.
kanban card status

The current state of the kanban card - Active, on Hold, or Canceled.
kanban card supply status

Describes the current state in the replenishment process. Example: New, Empty,
Full, Wait, In Process, In Transit.
5
kanban chain
A series of kanban pull sequences that model the replenishment network on the
shop floor.
kanban items
An item that is pulled through the Kanban system, rather than pushed by the
planner, is called a Kanban-released item, or simply Kanban item. Your planning
system can have Kanban items as well as items released by the planner.
kanban location
The designated location where a kanban bin is stored (and where the replenishment
is delivered). In Oracle, this is a combination of sub-inventory and locator.
kanban plan
A set of kanban pull sequences in which the size or number of cards is calculated
based on a given demand schedule.
kanban pull sequence

A body of information that defines the kanban location, source information, and
planning parameters required to calculate the kanban size for a given kanban bin.
Replenishment chains are created by multiple pull sequences.
kanban replenishment lead time

The time it takes to replenish a given pull sequence.
kanban size
The number of items in each kanban bin.
labor time
The sum of all labor resource times for a given event on a flow routing.
last unit completion date

The date and time you plan to complete production of the last assembly on a
repetitive schedule. This date equates to the first unit completion date plus
processing days.
6
last unit start date
The date and time you plan to begin production of the last assembly on a repetitive
schedule. This date is the first unit start date plus processing days.
line balancing
Organizing work on the production line so that resources can by synchronized to
daily demand.
line operations
Re-grouping of events on a flow routing to achieve approximate takt time. Line
operations are line specific and are derived and defined during line balancing.

A form where a WIP scheduler can access the data and utilize a suite of tools to
effectively manage flow schedules.
lines
Lines are manufacturing work areas where you manufacture families of products.
location
A shorthand name for an address. Location appears in address lists of values to let
you select the correct address based on an intuitive name.
machine time
The sum of all machine resource time for a given event on a flow routing.
mixed model map

Used to design balanced lines. The projected volume and mix of demand for a
group of products is used to calculate weighted average work content times. These
averages are compared to takt time to regroup events into balanced operations, and
reallocate resources.
7
N
net planning percent

Percent of product that passes through a process or line operation. It equals the sum
of the product of the network percentages at each operation along each path
multiplied by 1 + the rework percent.
non-replenishable kanban
A non-replenishable Kanban is used to replenish a Kanban location once. This card
is used typically for custom products, one-time customer orders or sudden spikes in
demand.
operation time
In discrete manufacturing, operation time is the total of setup and run time for a
specific task. In flow manufacturing, operation times includes the machine time,
labor time, and elapsed time for events, processes, and line operations on your flow
routing.
operation yield
The percent of material that passes through an operation, process or event on a flow
line without being scrapped.
operational cycle time

See takt Time.
Operational Method Sheet Support

Operational Method sheets (OMS) are documents that describe the operation to be
performed for an assembly. The information in the OMS often includes graphical
representation of the process, material needed, and detailed work instructions. You
can use attachments in Oracle Flow Manufacturing to attach OMS’s to Line
Operations in the Flow Routing.
Phantom
It is an item or a component which is never stocked and is used as a part in building
the final item. A phantom may further be made up of phantoms.
8
Point of Use (POU)
Inventory located at a specific operation on a flow line where it will be used.
Material is pulled from these locations via a Kanban signal. These locations are in
turn, supplied from either raw material stores or ideally, directly from the supplier.
process
A set of Oracle Workflow activities that need to be performed to accomplish a
business goal. see Account Generator, process activity, process definition.
Process
1) A planned series of actions or operations (e.g. mechanical, electrical, chemical,
inspection, test) that advances a material or procedure from one stage of completion
to another. 2) A planned and controlled treatment that subjects materials or
procedures to the influence of one or more types of energy (e.g. human, mechanical,
electrical, chemical, thermal) for the time required to bring about the desired
reactions or results. In flow manufacturing, processes are very generic activities on a
flow routing that often consist of several events that are performed in a specific
sequence. They are specific to a line and are often defined during the as-is analysis
on a flow line.
process network
You can use Flow Routings to represent the network processes on your production
line. This network can include alternate processes, rework loops and feeder lines.
You can assign yields and planning percentages for each of these processes to
determine the optimal number of resource requirements.
process volume
In the Oracle Mixed Model Map, the quantity of an assembly that must pass
through an operation or process to achieve the line demand volume. It equals the
(demand times * average planning percent * boost%)/average reverse cumulative
yield.
processes and events

Processes are very generic activities (in other words painting) that often comprise of
multiple events (in other words prepare the surface, polish the surface, paint the
surface) which are performed in a specific sequence. Events are the actual physical
tasks performed on the line. You can define standard processes and standard events
that are used consistently across product families and production lines.
9
product family
A group of products with similar characteristics, often used in production planning.
Flow product families often have similar product synchronization.
product structure
See production line
The physical location where you manufacture a repetitive assembly, usually
associated with a routing. You can build many different assemblies on the same line
at the same time. Also known as assembly line.
product synchronization (Sync)

Process of defining events, processes, and operations and assigning them to a flow
routing in a specific sequence in which they are performed.
productivity
An overall measure of the ability to produce a good or a service. It is the actual
output of production compared to the actual input of resources. Productivity is a
relative measure across time or against common entities (labor, capital, etc.).
products and parts

Products and parts are similar to items defined in Oracle Manufacturing. The item
type attribute can be used to identify different types of items (for example, finished
goods, spare parts, and so on).
production lines
Production Lines are manufacturing work areas where you manufacture families of
products. Oracle Flow Manufacturing lets you manage flow production activities by
production line. You can use Flow Routings to define the production process of
assemblies. You can also use the Mixed Model Map to calculate the line takt time.
pull sequences
See kanban pull sequence.
replenishable kanban
A replenishable Kanban card cycles through the system until it is put on temporary
hold or completely removed from the replenishment cycle by the user.
10
return from scrap transaction
This transaction is used for returning scrapped assemblies. In this document Return
from Scrap transaction will mean CFM return from scrap.
reverse cumulative yield

Product of the yields at each operation, process, or event on a flow line starting with
the last operation, process, or event.
roll flow schedules

An Oracle Manufacturing technique where you can copy the flow schedules you
did not complete into the next available day or take over-completions and subtract
the total from the quantities of future schedule.
routing network
Routing network defines the flow of work from one line operation to the next. It
also specifies which path in the routing is an alternate or rework path. Routing
networks, line operations, and events are the only entities considered in WIP.
sales order
In this document a sales order by default means an ATO sales order.
scheduled flow schedule

These are flow schedules that are created by planning with a specific scheduled
completion date.
scheduling rule
Basic rules that can be used consistently in a scheduling system. Scheduling rules
usually specify the amount of calendar time to allow for a move, queue, load
calculation, etc. Syn: scheduling algorithm.
scrap account
An account that you may use to charge scrap transactions.
scrap line operation

This is the line operation in the flow routing that the assembly is scrapped.
11
scrap transaction
This transaction is used for scrapping assemblies. In this document Scrap
transaction will mean CFM scrap transaction.
takt time
Operation cycle time the rate at which products need to be manufactured on the
line. Aids in establishing the daily rate for the production line. takt Time=effective
resource hours available per day / Average daily demand.
Total Product Cycle Time (TPCT)

The total time along the longest path of your flow routing. Calculated by taking the
sum of the elapsed times along the longest primary path on the routing network.
unscheduled flow schedule

These are ad-hoc flow schedules that are created on the fly so that a completion or
return can be performed for an assembly.
Utilization
A measure to describe how intense a resource is being used. Utilization measures
the actual time used to the total available time. Utilization = actual time used / total
available time. Actual time used is the total processing time and setup time in a
given time period. Total available time is the total available hours in a given time
period minus the total time the resource is down for repair or maintenance.
work order-less completion

A process which allows you to complete both scheduled and unscheduled flow
assemblies and automatically backflush Operation Pull, Assembly Pull and Push
components, their associated costs, and labor and machine resources used without
having to create a discrete job, repetitive schedule or flow schedule.
yield
See component yield, cumulative yield, operation yield, and reverse cumulative
yield.
12
Index
A E
Add Item Routing window, 4-18 ECO Checking, 10-5, 10-28
Algorithms, 7-23 Entering Mixed Model Map Parameters, C-3
Alternate Event window, 4-39
for routings, 3-10
Attributes
F
for sequencing, 6-4
viewing and defining, 6-8 Feeder Line Synchronization window, 8-2
Auto Request Filtering demands for a sequencing task, 6-25
Outbound Broadcast Sequencing, 11-13 Filter/Sort Criteria window, 5-24
Flexible tolerance fences, 7-9
B completions, 10-16
Balancing a Flow Manufacturing line, 3-8 customized properties region, 10-28
detail properties, 10-25
Event page, 10-15
C
instructions, 10-21
Calculating Operation Times, 3-15 integration with Oracle Quality, 10-27
Calculating Operation Yields, 3-19 Line Operation page, 10-13
Completing line operations, 10-16 overview, 10-2
Conflict Resolution window, 11-36 preferences, 10-3
Constraints preferences, Schedule page, 10-12
defining, 6-13 resources, 10-20
for sequencing, 6-5 setting up, 10-2
Creating a Flow Routing, 3-9 user entered mode, 10-12
Cumulative Yield, 3-22 work queue mode, 10-10
Flow Manufacturing
D creating a Flow Routing, 3-9
defining Standard Events, 3-5
Defining Standard Events, 3-5 defining Standard Processes, 3-4
Defining Standard Line Operations, 3-7 Flow Manufacturing Sequencing and Execution
Defining Standard Processes, 3-4 Home page, 6-3
Demand Graph tab, 11-23 Flow Routing
1
creating, 3-9 I
Flow Schedule Summary window, 7-18
Instructions page, 10-21
Flow schedules
IPK Assignment
calculation of, 7-23
Mixed Model Map Workbench, 5-22
completing, 7-25
Item Details window, 5-16
component availability, 7-32
Item window, 11-9
creating, 7-15
deleting, 7-29
detail level, 7-20 K
modifying, 7-19
Kanban Demand window, 11-25
rolling forward, 7-25
Kanban Detail window, 11-25
summary window, 7-18
viewing, 7-18
viewing and creating from line scheduling L
workbench, 7-8 Launching a kanban plan, 11-34
Level daily rate, 7-4
G Line Balance, 3-8
Line Operation
Generating a Mixed Model Map, C-4
Mixed Model Map Workbench, 5-13, 5-14
Graphical Kanban Workbench
Line Operation window, 4-37
color representation, 11-2
Line Scheduling Preferences window, 7-31
navigating, 11-2
Overview, 11-2
ATP results, 7-32
Planning region, 11-19
completing flow schedules, 7-25
Pop-up Menus, 11-4
creating flow schedules, 7-15
Toolbar, 11-3
deleting flow schedules, 7-29
Tools menu, 11-3
overview of, 7-2
Graphical Line Designer Workbench
scheduling algorithms, 7-4
adding events, 4-32
scheduling rules, 7-3
adding line operations, 4-30
sequencing criteria, 7-4
adding processes, 4-31
Tools menu, 7-25
modifying Operation Line Tree and Process
viewing unscheduled orders, 7-10
Tree, 4-36
Line scheduling workbench
modifying the network, 4-29
synchronizing lines, 8-2
modifying the Operation Line Tree and Process
viewing, creating, modifying flow
Tree, 4-36
schedules, 7-8
navigating, 4-3
Line Scheduling Workbench Options window, 7-8
Item Routing window, 4-18
Line Scheduling Workbench Tools menu, 7-25
Related Routings window, 4-20
Linearity Report, 12-4
overview, 4-2
Lines
pop up menus, 4-8
detail graphical view on Mixed Model Map
template routings, 4-41
Workbench, 5-12
toolbars, 4-5
detail resource and IPK view on Mixed Model
Map Workbench, 5-11
detail summary view on Mixed Model Map
2
Workbench, 5-9 setting up, 9-2
summary view on Mixed Model Map Overview of
Workbench, 5-8 Flow Manufacturing, 1-1
Flow Schedule Sequencing, 6-2
Mixed Model Map Workbench, 5-2
M
Outbound Broadcast Sequencing, 9-2
Mixed Model Map
Calculations, C-10
calculations, C-10
P
generating, C-4 Pegging tab, 11-24
overview, C-2 Plan Resource
parameters, C-2 viewing on the Mixed Model Map
placing on the navigator, C-9 Workbench, 5-16
querying a Saved Baseline, C-8 Planning region, 11-19
querying a saved baseline, C-8 Process window, 4-38
resource detail views, 5-19 Product Synchronization, 3-2
saving a Baseline, C-7 for product family items, 3-3
saving a baseline, C-7 for standard items, 3-2
Mixed Model Map Workbench Production
filtering and sorting, 5-24 updating, 11-34
In Process Kanbans, 5-22 Production lines
item details, 5-16 assigning to a rule, 6-19
line summary view, 5-8 sequencing, 6-7
overview, 5-2 viewing and updating, 6-16
plan, 5-7 production lines and line operations, 5-7
plan resource information, 5-16 Production region, 11-5
resource assignment, 5-21 Pull Sequence window, 11-12
viewing, creating, and updating plans, 5-4
Q
N Querying a saved baseline, C-8
Net Planning, 3-21
Network Connection window, 4-34, 4-41
R
No level loading, 7-4
Related Routings window, 4-20
Replenishing Kanban cards, 10-26
O Replenishment Chain tab, 11-23
Operation Times, 3-15 Reports
Operation Times Calculations, 3-16 Linearity, 12-4
Operation Yields Schedule, 12-2
calculating, 3-19 Resource Assignment
Operation Yields Calculations, 3-20 Mixed Model Map, 5-21
Outbound Broadcast Sequencing, 9-2 Reverse Cumulative Yield, 3-23
Auto Request box, 11-13 Rolling flow schedules forward, 7-25
process flow, 9-3 Routing Details window, 4-28
3
Routing Network, 3-14 quantities across workdays, 7-19
creating, 3-14 Standard Events, 3-5
Routing revision, 3-10 Standard Line Operations
Rules defining, 3-7
for sequencing, 6-7 Standard Processes, 3-4
viewing sequencing rules, 6-10 for a flow manufacturing line, 3-4
S T
Saving a Baseline, C-7 Template Routings, 4-41
Schedule Report, 12-2 Tolerance fences, 7-9
Scheduling algorithms, 7-4, 7-23 Total Product Cycle Time, 3-18
level daily rate, 7-4 calculating, 3-18
Scheduling rules
defining, 7-3
U
defining system or user rules, 7-6
options, 7-3 Updating production, 11-34
viewing existing rules, 7-6 conflict resolution, 11-36
Scheduling algorithms User Entered Mode, 10-12
mixed model, 7-4
no level loading, 7-4 W
Sequencing
adjusting sequencing task results, 6-26 Work Queue Mode, 10-10
attributes, 6-4
constraints, 6-5
creating sequencing tasks, 6-22
entering sequencing task parameters, 6-23
filtering demands for a task, 6-25
moving demand, 6-31
resequencing Tasks, 6-34
rules, 6-7
sequencing engine concurrent request, 6-28
setting up, 6-4
splitting demand, 6-33
task details and results page, 6-37
updating demand, 6-32
updating line task parameters, 6-28
viewing rules, 6-10
viewing tasks, 6-34
Sequencing criteria, 7-4
Setting Up
Flow Execution Workstation, 10-2
Objectives, 2-2
Steps, 2-3
Spreading

11.5.10 Flow Manufacturing

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Oracle® Flow Manufacturing

Part No. A69396-04

Copyright © 1999, 2004, Oracle. All rights reserved.

Primary Author: Susan Saperstein

Contributing Authors: Valerie Dubois, Richard Rodgers, Adrian Suherman

Send Us Your Comments ................................................................................................................... xi

1 Overview of Flow Manufacturing

3 Line Design and Balancing Procedures

4 Graphical Line Designer Workbench

5 Mixed Model Map Workbench

7 Line Scheduling Workbench

9 Outbound Broadcast Sequencing

10 Flow Execution Workstation

11 Graphical Kanban Workbench

12 Reports and Processes

A Windows and Navigation Paths

B Line Scheduling Calculation Examples

C Mixed Model Map

Welcome to the Oracle Flow Manufacturing User’s Guide, Release 11i.

■ Chapter 1: Provides an overview of the features in Flow Manufacturing.

Accessibility of Code Examples in Documentation

Accessibility of Links to External Web Sites in Documentation

Other Information Sources

Guides Related to All Products

Oracle Applications User’s Guide

User Guides Related to This Product

Oracle Advanced Planning Implementation and User’s Guide

Oracle Bills of Material User’s Guide

Oracle Cost Management User’s Guide

Oracle General Ledger User’s Guide

Oracle Inventory User’s Guide

Oracle Order Management User’s Guide

Oracle Purchasing User’s Guide

Oracle Quality User’s Guide

Oracle Work in Process User’s Guide

Installing Oracle Applications

Upgrading Oracle Applications

Maintaining Oracle Applications

Oracle Alert User’s Guide

Oracle Applications Developer’s Guide

Oracle Applications User Interface Standards for Forms-Based Products

Other Implementation Documentation

Oracle Applications Product Update Notes

Multiple Organizations in Oracle Applications

Oracle Applications Flexfields Guide

Oracle eTechnical Reference Manuals

Oracle Manufacturing APIs and Open Interfaces Manual

Oracle Applications Message Reference Manual

Training and Support

Do Not Use Database Tools to Modify Oracle Applications Data

Overview of Flow Manufacturing 1-1

Overview of Flow Manufacturing

1-2 Oracle Flow Manufacturing User’s Guide

Overview of Flow Manufacturing 1-3

Line Design and Balancing

1-4 Oracle Flow Manufacturing User’s Guide

Mixed Model Map Workbench

Overview of Flow Manufacturing 1-5

■ Increasing resource (machine, labor) capacity

Operation Method Sheets