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R12: Asset Tracking for Depreciable Items

As discussed in the earlier article Asset Tracking is all about two kinds of items: Depreciable and Normal Items. I already discussed normal items with simple inventory transactions earlier. Let us discuss depreciable items in this article. This is very peculiar situation where you will be receiving items into inventory and at the same time depreciating them by creating assets while it is sitting in your inventory.
Sounds odd but this is reality in a number of asset intensive industries. Take construction industry for example. All the equipment and material that is required to construct a plant or a building is typically stored on site. Here we should be able to keep track of inventory from planning perspective and at the same time some of the items while sitting in inventory on site. Asset tracking for depreciable items comes handy here.
The flow is very simple. You receive items against a purchase order and run one program which creates an asset for you in Fixed Assets. From then on the asset starts getting depreciated. But where it gets tricky is in accounting. Since we are receiving this into inventory as well as creating an asset in fixed asset, potentially we are counting the asset value twice. An asset value can be in inventory or assets not both. So how Oracle handles this? Also what happens if we dispose of or sell this asset? Let us examine the accounting entries for each transaction to understand this.
Take a case. Donald Drumps Construction Company is constructing a huge building in the suburbs of New York. A forklift was required to be purchased for the construction needs. This forklift is treated as an asset hence required to be created as asset. Hence a purchase order was raised and sent to the supplier to be delivered at the construction site. It costs $150,000 and the company uses standard costing.
Each construction site can be assigned a different organization or a Subinventory within an organization. A location should be created for this construction site in New York and assigned to this Subinventory. Important attributes in the item master to be enabled are shown here.
When the supplier sends forklift against this PO, someone on site receives into inventory. As soon it is received into inventory, IB gets created, marking the transaction (csi_transactions) ready to be processed for asset creation.
Accounting for PO Receipt transaction into Inventory is as shown here.
 Now as per the flow running the program Create Assets: Interface Inventory Transactions to Assets will interface the asset to the fixed assets taking this information from IB and inventory. Creation of assets also involves in an accounting entry as the asset value is increasing. So the accounting in this transaction is:
As you can see here, inventory account is used to credit, debiting the asset account taken from the asset category assigned to the item in the item master. So the inventory value goes down in balance sheet increasing the asset value from fixed asset. All this is happening at cost of the item. And the asset starts depreciating for the period of the project.
What happens after the building construction is done?
Out of a number of possibilities, two things can happen. This forklift can be moved to another site where construction is going on or simply after the project is successfully completed, this can be sold right from the site to another smaller construction company. If it is moved to another site (considered as Asset Move in Asset Tracking) depending on how the other site is configured in the system (different organization mapped to different asset book or same asset book), treatment in assets is different. But let us take the case where Mr. Drump is tired of this asset and would like to sell it off. Since quantity exists in inventory we can create a sales order and ship it. When you ship accounting is (assuming that he is selling at 60% of the cost as the equipment is already used):
 This is not good. As you can see we credited Inventory account twice. Once when we are creating asset and once shipping this forklift after usage. Also since we have shipped the asset to someone else, Mr. Drump should retire this asset from asset books by retiring the asset.
Asset Tracking handles this well. Inventory sends this shipping transaction message to IB which identifies the transaction to be eligible for asset retirement. Another program, called Interface Move Transactions to Assets is run to send the retirement message to Fixed Assets from IB. Asset retirement ensues.
But what about crediting the inventory account twice? To solve this issue there is another program we need to run to reverse the shipping accounting: Create Reversal GL entries For Inventory FA Items. This program identifies transactions that are eligible (rows in csi_transactions table with gl_interface_status_code flag set to 1) and inserts rows into gl_interface for importing into GL. So when you run this program, accounting is:
You can see that COGS account is not touched as revenue is involved and only Deferred COGS is touched. This might surprise you because, you thought, with the advent of Subledger Accounting, all transactions from sub-ledgers to GL flow through the Subledger Accounting application. Here is one accounting entry flowing into GL without Subledger accounting, making reconciliation harder for inventory.
Moreover this left credit balance in my deferred COGS account as you figured it out!
Points to consider:

  • Don’t be surprised to see inventory account having the source of Assets when reconciling inventory to GL. Also accounting flows from Asset Tracking but with the source of Inventory (reversals).
  • What happens to all those reports that are used to match the inventory value by quantity and inventory value in inventory account? The will not match here because quantity very well exists but the value in the account got credited elsewhere in assets and not in the inventory in of form of an issue.
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R12: Introduction to Asset Tracking

What is Asset Tracking?
Asset Tracking in R12 (formerly known as Enterprise Installed Base), provides the functionality of operational and financial tracking of assets that are deployed in the feild as well as that are in inventory.
Assets in Procure to Pay
Traditionally we  have been creating assets in Fixed Assets using the Procure to Pay business flow. These POs have destination type as expense and not as inventory. Once the PO is matched to Invoice, Mass Additions Create Program sends assets to Mass Additions interface.
On the other hand Asset Tracking can create assets that are purchased into Inventory. While still being in Inventory, assets are created in fixed assets and depreciated. Operationally these assets are tracked in this application using the Installed Base’s current location. It uses Installed Base functionality as backbone to track the location of the assets.
Features of Asset Tracking
Asset Tracking is all about two kinds of items : Depreciable Items and Non-depreciable items. Depreciable items are those that depreciate while still being in Inventory. Non-Depreciable items are those that are still tracked as assets and depreciated while being “deployed” in the field (issued to field location or a project).
Foremost requirement for tracking an asset in this application is that the item is Intalled Base trackable. This is an attribute maintained in the item master. Using the integration between Inventory and Installed Base, all depreciable items, are created as assets as soon they are received into inventory.
All transactions coming from inventory and deployment transactions of Asset Tracking are tracked in Installed Base against the instance of this asset. Also Instance is linked to the financial asset in the installed base.
This application tracks the asset life cycle. When a depreciable item is received into inventory, asset gets created, but when it is sold or issued out the asset gets retired. On the otherside non-depreciable items are created as assets only when they are deployed not when they are in Inventory.
Alternatively assets can be created in the Fixed Assets first and then created in Asset Tracking, which automatically ties the asset and instance in Installed Base.
Integration of Asset Tracking
Integration of Asset TrackingAsset Tracking inherits all the integration that is out there for the Installed Base with other products. Asset Tracking integrates the operational aspects of the installed base with financial aspects of assets.
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API for Closing/Finally Closing PO Using po_actions.close_po

Do we have any API for Finally Closing PO??
Yes, we are having an API for closing or finally closing the POs. In the API, there is a parameter “p_action” which we need to set as either CLOSE (if we want to close the PO) or FINALLY CLOSE (If we want to Finally Close) the PO. Another Parameter which needs to set properly is “p_auto_close”. This parameter should be set to ‘N’.
— R12 – PO – Script to Close / Finally Close PO using PO_ACTIONS CLOSE_PO API.sql

DECLARE

x_action constant varchar2(20) := ‘FINALLY CLOSE’; — Change this parameter as per requirement
x_calling_mode constant varchar2(2) := ‘PO’;
x_conc_flag constant varchar2(1) := ‘N’;
x_return_code_h varchar2(100);
x_auto_close constant varchar2(1) := ‘N’;
x_origin_doc_id number;
x_returned boolean;

CURSOR c_po_details IS

SELECT
pha.po_header_id,
pha.org_id,
pha.segment1,
pha.agent_id,
pdt.document_subtype,
pdt.document_type_code,
pha.closed_code,
pha.closed_date
FROM apps.po_headers_all pha, apps.po_document_types_all pdt
WHERE pha.type_lookup_code = pdt.document_subtype
AND pha.org_id = pdt.org_id
AND pdt.document_type_code = ‘PO’
AND authorization_status = ‘APPROVED’
AND pha.closed_code <> ‘FINALLY CLOSED’
AND segment1 = ‘379329’; — Enter the PO Number if one PO needs to be finally closed/Closed

begin

fnd_global.apps_initialize (user_id => 1805,
resp_id => 20707,
resp_appl_id => 201);

for po_head in c_po_details

LOOP

mo_global.init (po_head.document_type_code);
mo_global.set_policy_context (‘S’, po_head.org_id);

DBMS_OUTPUT.PUT_LINE (‘Calling PO_Actions.close_po for Closing/Finally Closing PO =>’ po_head.segment1);

x_returned :=
po_actions.close_po(
p_docid => po_head.po_header_id,
p_doctyp => po_head.document_type_code,
p_docsubtyp => po_head.document_subtype,
p_lineid => NULL,
p_shipid => NULL,
p_action => x_action,
p_reason => NULL,
p_calling_mode => x_calling_mode,
p_conc_flag => x_conc_flag,
p_return_code => x_return_code_h,
p_auto_close => x_auto_close,
p_action_date => SYSDATE,
p_origin_doc_id => NULL);

IF x_returned = TRUE THEN

DBMS_OUTPUT.PUT_LINE (‘Purchase Order which just got Closed/Finally Closed is ‘ po_head.segment1);

COMMIT;

ELSE

DBMS_OUTPUT.PUT_LINE (‘API Failed to Close/Finally Close the Purchase Order’);

END IF;

END LOOP;

END;

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Reprocessing Period Close Pending Transactions


Unprocessed Transaction Messages While Closing the Inventory Accounting Period

While closing the inventory accounting periods, If there are unprocessed transactions, then one of the following messages appears:

Pending receiving transactions for this period
When you use Purchasing, this message indicates you have unprocessed purchasing transactions in the RCV_TRANSACTIONS_ INTERFACE table. These transactions include purchase order receipts and returns for inventory. If this condition exists, you will receive a warning but will be able to close the accounting period. These transactions are not in your receiving value. However, after you close the period, these transactions cannot be processed because they have a transaction date for a closed period.

Unprocessed material transactions exist for this period

This message indicates you have unprocessed material transactions in the MTL_MATERIAL_TRANSACTIONS_TEMP table. You are unable to close the period with this condition. Please see your system administrator. Inventory considers entries in this table as part of the quantity movement.

Closing the period in this situation is not allowed because the resultant accounting entries would have a transaction date for a closed period, and never be picked up by the period close or general ledger transfer process.

Pending material transactions for this period

This message indicates you have unprocessed material transactions in the MTL_TRANSACTIONS_INTERFACE table. If this condition exists, you will receive a warning but will be able to close the accounting period. These transactions are not in your inventory value. However, after you close the period, these transactions cannot be processed because they have a transaction date for a closed period.

Uncosted material transactions exist for this period

This message indicates you have material transactions in the MTL_MATERIAL_TRANSACTIONS table with no accounting entries (Standard Costing) and no accounting entries and no costs (Average Costing). You are unable to close the period with this condition. These transactions are part of your inventory value.

Closing the period in this situation is not allowed because the resultant accounting entries would have a transaction date for a closed period, and never be picked up by the period close or general ledger transfer process.

Pending move transactions for this period

This message indicates you have unprocessed shop floor move transactions in the WIP_MOVE_TXN_INTERFACE table. If this condition exists, you will receive a warning but will be able to close the accounting period. These transactions are not in your work in process value. However, after you close the period, these transactions cannot be processed because they have a transaction date for a closed period.

Pending WIP costing transactions exist in this period

This message indicates you have unprocessed resource and overhead accounting transactions in the WIP_COST_TXN_INTERFACE table. You are unable to close the period with this condition. These transactions are in your work in process value, and awaiting further processing.

Closing the period in this situation is not allowed because the resulting accounting entries would have a transaction date for a closed period, and never be picked up by the period close or general ledger transfer process.

Reprocessing Period Close Pending Transactions:

There are a variety of reasons for pending transactions, which we have discussed above. This following document will serve as a guide for troubleshooting and processing pending transactions preventing an accounting period from being closed.

When resolving and working with Pending Transactions users must collect and identify data in order to address the source product and complete the Period Close process.

Hence the key steps for resolving pending transactions are:

– Locate the transactions
– Find the error message to determine what is preventing the transactions from processing.
– Resolve the error
– Resubmit the pending record.

/*SCRIPT TO IDENTIFY PENDING TRANSACTIONS & STEPS TO REPROCESS THEM
================================================================*/

— Pending Move Transactions

select mti.*
from wip_move_txn_interface mti,
org_organization_definitions org
where mti.organization_id = org.organization_id
and trunc(mti.creation_date) > to_char(TRUNC(to_date(’01-JUL-2009′,’DD-MON-YYYY’)))

select organization_code,count(*)
from wip_move_txn_interface mti
group by organization_code

select mti.organization_id,mti.organization_code,org.organization_name,count(*)
from wip_move_txn_interface mti,
org_organization_definitions org
where mti.organization_id = org.organization_id
and trunc(mti.creation_date) > to_char(TRUNC(to_date(’01-JUL-2009′,’DD-MON-YYYY’)))
group by mti.organization_id,mti.organization_code,org.organization_name

select mti.organization_id,mti.organization_code,org.organization_name,count(*) from
wip_move_txn_interface mti,
wip_txn_interface_errors emsg,
mtl_system_items msi,
org_organization_definitions org
where mti.transaction_id = emsg.transaction_id
and mti.primary_item_id = msi.inventory_item_id(+)
and mti.organization_id = msi.organization_id(+)
and mti.organization_id = org.organization_id
and mti.process_status = 3
and trunc(mti.creation_date) > to_char(TRUNC(to_date(’01-JUL-2009′,’DD-MON-YYYY’)))
group by mti.organization_id,mti.organization_code,org.organization_name

— Script to Reprocess Pending Move Transactions
update wip_move_txn_interface
set group_id=null,
request_Id = null,
process_status=1,
transaction_id=null
where process_status=3
and Transaction_id = &Transaction_id — Enter the transaction_id which you want to reprocess

–Pending Resource Transactions

select wct.*
from wip_cost_txn_interface wct,
org_organization_definitions org
where wct.organization_id = org.organization_id
and trunc(wct.creation_date) > to_char(TRUNC(to_date(’01-JUL-2009′,’DD-MON-YYYY’)))

select wct.*
from wip_cost_txn_interface wct,
org_organization_definitions org
where wct.organization_id = org.organization_id
and trunc(wct.creation_date) > to_char(TRUNC(to_date(’01-JUL-2009′,’DD-MON-YYYY’)))
and wct.process_status = 3

select wct.*
from wip_cost_txn_interface wct,
org_organization_definitions org
where wct.organization_id = org.organization_id
and trunc(wct.creation_date) > to_char(TRUNC(to_date(’01-JUL-2009′,’DD-MON-YYYY’)))
and wct.process_status = 3

select wct.organization_id,wct.organization_code,wct.process_status,org.organization_name,count(*)
from wip_cost_txn_interface wct,
org_organization_definitions org
where wct.organization_id = org.organization_id
and trunc(wct.creation_date) > to_char(TRUNC(to_date(’01-JUL-2009′,’DD-MON-YYYY’)))
and wct.process_status = 3
group by wct.organization_id,wct.organization_code,wct.process_status,org.organization_name

select wcti.organization_code,wtie.error_message,wtie.error_column,wcti.transaction_id,
wcti.transaction_date,wcti.creation_date,wcti.process_phase,wcti.process_status,
we.wip_entity_name,msi.segment1,wcti.operation_seq_num,wcti.resource_seq_num,
wcti.transaction_quantity,wcti.transaction_uom,wcti.primary_uom,wcti.move_transaction_id
from wip_cost_txn_interface wcti,
wip_txn_interface_errors wtie,
wip_entities we,
mtl_system_items msi
where wcti.organization_id = msi.organization_id
and wcti.organization_id = we.organization_id
and wcti.primary_item_id = msi.inventory_item_id
and wcti. wip_entity_id = we.wip_entity_id
and wcti.transaction_id = wtie.transaction_id
and trunc(wcti.creation_date) > to_char(TRUNC(to_date(’01-JUL-2009′,’DD-MON-YYYY’)))
and wcti.process_status = 3
order by wcti.organization_code

— Script to reprocess Pending Resource Transactions
update wip_cost_txn_interface
set group_id=NULL,
transaction_id = NULL,
process_status= 1
where process_status = 3
and Transaction_id = &Transaction_id — Enter the transaction_id which you want to reprocess

— Transaction Open Interface

select mti.*
from mtl_transactions_interface_v mti,
org_organization_definitions org
where mti.organization_name = org.organization_name
and trunc(mti.creation_date) > to_char(TRUNC(to_date(’01-JUL-2009′,’DD-MON-YYYY’)))

select mti.creation_date,mti.process_flag,mti.process_flag_desc,mti.error_explanation,
mti.error_code,mti.transaction_interface_id,mti.transaction_header_id,
mti.source_code,mti.transaction_source_type_name,mti.transaction_type_name,mti.source_header_id,
mti.source_line_id,mti.transaction_mode,mti.transaction_mode_desc,mti.organization_id,
mti.organization_code,mti.organization_name,mti.inventory_item_id,mti.transaction_source_id
from mtl_transactions_interface_v mti,
org_organization_definitions org
where mti.organization_name = org.organization_name
and trunc(mti.creation_date) > to_char(TRUNC(to_date(’01-JUL-2009′,’DD-MON-YYYY’)))
and process_flag = 3
order by organization_id,organization_code,organization_name

select mti.organization_id,mti.organization_code,mti.organization_name,mti.process_flag,count(*)
from mtl_transactions_interface_v mti
where trunc(mti.creation_date) > to_char(TRUNC(to_date(’01-JUL-2009′,’DD-MON-YYYY’)))
and mti.process_flag = 3
group by organization_id,organization_code,organization_name,mti.process_flag

— Script to Process the errored Records from Transactions Open Interface
update mtl_transactions_interface
set process_flag = 1,
lock_flag = 2,
transaction_mode = 3,
validation_required = 1,
error_code = null,
error_explanation = null
where organization_id = &Organization_id
and process_flag = 3
and transaction_interface_id = &transaction_interface_id

— Pending Material Transactions

select * from mtl_material_transactions_temp
where trunc(creation_date) > to_char(TRUNC(to_date(’01-JUL-2009′,’DD-MON-YYYY’)))

select mmtt.*
from mtl_material_transactions_temp mmtt,
org_organization_definitions org
where mmtt.organization_id = org.organization_id
and trunc(mmtt.creation_date) > to_char(TRUNC(to_date(’01-JUL-2009′,’DD-MON-YYYY’)))

select mmtp.organization_id,org.organization_code,org.organization_name,count(*)
from mtl_material_transactions_temp mmtp,
org_organization_definitions org
where mmtp.organization_id = org.organization_id
and trunc(mmtp.creation_date) > to_char(TRUNC(to_date(’01-JUL-2009′,’DD-MON-YYYY’)))
group by mmtp.organization_id,org.organization_code,org.organization_name

select count(*),mmtt.error_code,mmtt.error_explanation,org.organization_id,org.organization_code,org.organization_name,org.operating_unit
from mtl_material_transactions_temp mmtt,
org_organization_definitions org
where org.organization_id = mmtt.organization_id
and trunc(mmtt.creation_date) > to_char(TRUNC(to_date(’01-JUL-2009′,’DD-MON-YYYY’)))
group by mmtt.error_code,mmtt.error_explanation,org.organization_id,org.organization_code,org.organization_name,org.operating_unit
order by org.organization_id

— Script to Reprocess the Pending Material Transactions

update mtl_material_transactions_temp
set process_flag = ‘Y’,
lock_flag = ‘N’,
transaction_mode = 3,
error_code = NULL,
error_explanation = NULL
where process_flag in (‘Y’,’E’)
and organization_id = &Organization_id
and transaction_temp_id = &transaction_temp_id

— Count Of Uncosted Transactions
select * from mtl_material_transactions
where trunc(creation_date) > to_char(TRUNC(to_date(’01-JUL-2009′,’DD-MON-YYYY’)))
and costed_flag is not null

select costed_flag,count(*)
from mtl_material_transactions
where trunc(creation_date) > to_char(TRUNC(to_date(’01-JUL-2009′,’DD-MON-YYYY’)))
and costed_flag is not null
group by costed_flag

select costed_flag,organization_id,acct_period_id,count(*)
from mtl_material_transactions
where trunc(creation_date) > to_char(TRUNC(to_date(’01-JUL-2009′,’DD-MON-YYYY’)))
and costed_flag is not null
and costed_flag = ‘E’
group by costed_flag,organization_id,acct_period_id

— Script to Reprocess the Costed Transactions

update mtl_material_transactions
set costed_flag = ‘N’,
transaction_group_id = NULL,
transaction_set_id = NULL,
request_id = NULL,
error_code = NULL,
error_explanation = NULL,
where (costed_flag = ‘E’ or costed_flag = ‘N’)
and transaction_id = &transaction_id

— Check for the Shipping Transaction Stuck in the Inventory Interface

SELECT wdd.delivery_detail_id, oe_interfaced_flag, inv_interfaced_flag
FROM wsh_trips wtr,
wsh_trip_stops wts,
wsh_delivery_legs wlg,
wsh_new_deliveries wnd,
wsh_delivery_assignments wda,
wsh_delivery_details wdd,
mtl_parameters mp
WHERE wtr.trip_id = wts.trip_id
AND wts.stop_id = wlg.pick_up_stop_id
AND wts.pending_interface_flag = ‘Y’
AND wlg.delivery_id = wnd.delivery_id
AND wnd.delivery_id = wda.delivery_id
AND wda.delivery_detail_id = wdd.delivery_detail_id
AND wdd.organization_id = mp.organization_id
AND mp.organization_code = ‘A66’ — Enter The Organization_code

SELECT wts.stop_id, wts.pending_interface_flag
FROM wsh_trips wtr,
wsh_trip_stops wts,
wsh_delivery_legs wlg,
wsh_new_deliveries wnd,
wsh_delivery_assignments wda,
wsh_delivery_details wdd,
mtl_parameters mp
WHERE wtr.trip_id = wts.trip_id
AND wts.stop_id = wlg.pick_up_stop_id
AND wts.pending_interface_flag = ‘Y’
AND wlg.delivery_id = wnd.delivery_id
AND wnd.delivery_id = wda.delivery_id
AND wda.delivery_detail_id = wdd.delivery_detail_id
AND wdd.organization_id = mp.organization_id
AND mp.organization_code = ‘A66’ — Enter The Organization_code
SELECT
wdd.source_header_id header_id,
ooh.order_number,
ool.line_number,
ool.shipment_number,
ool.line_id,
wnd.delivery_id,
wnd.NAME delivery,
wdd.delivery_detail_id,
wdl.pick_up_stop_id,
wdd.inv_interfaced_flag,
wdd.oe_interfaced_flag
FROM wsh_delivery_details wdd,
wsh_delivery_assignments wda,
wsh_new_deliveries wnd,
wsh_delivery_legs wdl,
wsh_trip_stops wts,
oe_order_headers_all ooh,
oe_order_lines_all ool
WHERE wdd.source_code = ‘OE’
AND wdd.released_status = ‘C’
AND wdd.inv_interfaced_flag IN (‘N’, ‘P’)
AND wdd.organization_id = &organization_id — Enter The Organization_id
AND wda.delivery_detail_id = wdd.delivery_detail_id
AND wnd.delivery_id = wda.delivery_id
AND wnd.status_code IN (‘CL’, ‘IT’)
AND wdl.delivery_id = wnd.delivery_id
AND TRUNC (wts.actual_departure_date) BETWEEN ’01-AUG-2009′ AND ’31-AUG-2009′
AND wdl.pick_up_stop_id = wts.stop_id
AND wdd.source_header_id = ooh.header_id
AND wdd.source_line_id = ool.line_id

— Steps to reprocess the pending shipping transactions

Verify that there are NO records for this Sales Order in the Pending Transactions Form or the Transaction Open Interface Form. Address the errors if any.
The records retrieved in these forms will list the Sales Order Number under the “Source” or “Transaction Source”columns for the Source TAB respectively.
Navigation> Inventory> Transactions> Pending Transactions
Navigation> Inventory> Transactions> Transaction Open Interface

For records with WSH_DELIVERY_DETAILS.OE_INTERFACED_FLAG or WSH_DELIVERY_DETAILS.INV_INTERFACED_FLAG values “P”,
please run the Interface Trip Stop process in Order Management to complete workflow for the Sales Order.
Navigation> Order Management> Shipping> Interfaces> Run > Select the Interface Trip Stop – SRS.

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Oracle Manufacturing Concepts

DISCRETE MANUFACTURING
Discrete manufacturing is a manufacturing process in which distinct items/products(which you can easily count, see and touch) are built or manufactured in discrete batches on manufacturing floor. It creates physical products which go directly to business and consumers, and assemblies that are used by other manufacturers. The resulting product is easily identifiable. It is different from process manufacturing where products are undifferentiated (can not tell the difference between one product and another) such as oil, natural gas and salt.

A typical characteristic of discrete manufacturing is the frequent switching from one manufactured product to another. The products are typically manufactured in individually defined lots, the sequence of work centers through production varying for each one of these. Costs are calculated on the basis of orders and individual lots

Discrete manufacturing is also characterized by individual or separate unit production. Units can be produced in low volume with very high complexity or high volumes of low complexity. Low volume/high complexity production results in the need for an extremely flexible manufacturing system that can improve quality and time-to-market speed while cutting costs. High volume/low complexity production puts high premiums on inventory controls, lead times and reducing or limiting materials costs and waste

Discrete manufacturing typically involves the sequence of work centers through which the products can pass during production. This sequence can be varied as per requirement. The order of work centers is determined in routing’s, which can often be very complex. There can be waiting times between the individual work centers. Also, semi-finished products are frequently placed in interim storage prior to further processing

Examples like Transportation equipment, Automobiles, toys, Computer and accessories and electronic products, consumer electronics, furniture, Lego Blocks, Appliances and other house hold items, Industrial and electrical equipment, Medical equipment and supplies, Fabricated metal, furniture, recycling, pencil ,light bulb, telephone, bicycle, Fuel Pump etc…

PROCESS MANUFACTURING
Process manufacturing is different from Discrete manufacturing. Manufacturing is not in discrete batches but is a process of pressing/mixing/chemical processing/heating/boiling liquid/semi liquid/solid and powder or raw materials. Once you manufacture a product by using process manufacturing, the output can not be brought to it’s original basic form

For example orange juice with sugar added cannot be put back in to the Orange and Sugar separately. On the other hand a computer manufactured by a discrete manufacturing process can be disassembled and the parts can be returned to stock to a large extent. Examples of process manufacturing are food products, beverages, paints & coatings, chemicals, specialty chemicals , pharmaceuticals, consumer packaged goods, Bulk drug pharmaceuticals, Nutraceutical, cosmeceutical and biotechnology industries. In Process Manufacturing, there are ingredients and not parts; there are formulas and not bill of materials; and bulk, not Unit of measure Each

FLOW MANUFACTURING

Flow Manufacturing is an innovative manufacturing method which synchronizes production with customer demand

Oracle Flow Manufacturing module supports the entire build-to-order manufacturing process which includes make-to-stock, configure-to-order, discrete-repetitive, assemble-to-order, and engineer-to-order manufacturing strategies and methods. It initiates schedules as soon as customer orders are received, and ensures shipment as soon as build is complete. Flow manufacturing employs pulls material using kanbans planning and back flushes material and costs upon completion. This in turn helps decrease inventories, optimize machine utilization, reduce response time to customer orders, and simplify shop floor activities.

Flow manufacturing production lines are designed to support the inter-mixed production of multiple products within a family on the same line at a constant rate. It can be used in Inventory module to replenish kanbans and in Work in Process to complete assemblies without having to create a job or a schedule (work order less job)

PROJECT MANUFACTURING
Large contracts or projects received by the companies can not be completely fulfilled by process manufacturing or discrete or repetitive manufacturing methods. It requires a separate manufacturing method known as project manufacturing. Project manufacturing meets demand driven production requirements for large contracts or projects. It allows you to plan, schedule, process and cost against a specific contract or a group of contracts or project for a specific customer.

Oracle Project Manufacturing supports companies in the Engineer-To-Order, Make-To-Order manufacturing strategies and Aerospace and Defense industries. These industries plan, track, procure, and cost based on project, contract, or Seiban numbers.

If Oracle Projects is installed and the Project References Enabled and Project Control Level parameters are set in the Organization Parameters window in Inventory module, you can assign project and, if required, task references to planned orders, jobs, purchase orders, sales orders, miscellaneous transaction and other entities within Oracle Manufacturing. If the Project Cost Collection Enabled parameter is also set in inventory organization parameters, you can optionally collect and transfer manufacturing cost to Oracle Projects module. Project costs are tracked by project/task and expenditure type.

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