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Shop Floor Manager (OSFM) and Business to Business (B2B) Tips and Tricks . Jerry Edwards. Definitions : Shop Floor Manager (OSFM): Lot centric and lot/serial number centric manufacturing product Stage: Product physical state and unit of measure. Semiconductor stages include:

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Presentation Transcript
slide2
Definitions:
  • Shop Floor Manager (OSFM): Lot centric and lot/serial number centric manufacturing product
  • Stage: Product physical state and unit of measure. Semiconductor stages include:
    • FAB, BUMP, SORT, DIE, ASSEMBLY, TEST, FGI
  • Adaptor: Custom software to generate Oracle application transactions based on vendor reported events
  • Binning: Process that results in multiple output parts based on process results (usually test)
slide3
Definitions: …continued
  • Event: Action affecting a product lot that vendor must report
  • Data element: specific data to support B2B communication and a specific Oracle application transaction
  • Business to Business Communications (B2B): Subcontractor manufacturing event communication and processing into Oracle purchasing, inventory, and OSFM application modules
slide4
Presentation Scope:
  • OSFMBest Practices
    • Product structure
    • Network routing suggestions
    • Tips and Tricks
    • Suggested Enhancements
    • Mapping subcontractors into OSFM
      • Single inventory organization for all vendors
      • Vendor specific inventory organizations
    • Business to Business (B2B) Functional Requirements
slide5
OSFM Product Structure Suggestions
  • Define separate part numberswhere:
    • subcontractors complete added value processes and move lots into stock or ship to other subcontractors
    • where wafers are converted to unassembled die
    • Typical stages: FAB / SORT / DIE/ASSEMBLED DIE / TESTED DIE / FINISHED DIE

OSFM Network Routing Suggestions

    • Start and complete work orders at one vendor for a single part number (stage)
    • Keep routings simple: add operations to track progress and to separate pay points.
    • Define alternate paths if required (rework for example)
slide6
OSFM TIPS & TRICKS
  • Co-Products: Use co-product %’s to enter test binning expected results to drive ASCP over-planning
    • Note: user must enter primary bill via co-products form to use this feature. User cannot enter bill via bill of material form and then add co-product %’s in co-products form
  • WIP Lot Bonus:
    • Starting job value is based on previous operation value
    • Start network routings with dummy IN operation and use WIP Lot Bonus at subsequent operations only.
    • Do not use WIP Lot Bonus into the first operation as component value is excluded resulting in inaccurate job costs
slide7
OSFM TIPS & TRICKS
  • Binning Process Options:
    • During Work Order: Perform WIP Split and update assembly for each bin. Note: Update assembly treats update as a move so do not use update assembly at operation with OSP resource or you will duplicate purchasing activity. Move lot to a non-OSP operation to prevent duplicate purchasing activity.
    • Post Work order: Complete work order, then perform Inventory lot split and Inventory lot translate for each bin to change the part numbers.
  • OSP Receiving:
    • Assign OSP resources so that quantity moved in will be correct OSP requisition quantity. For example: assembly charges for good quantity only. Assign OSP to operation after assembly.
    • Automate OSP receipts based on blanket releases.
slide8
OSFM TIPS & TRICKS
  • Supervisor Workbench versus Move form
    • Viewing many jobs versus playing transactions for specific jobs
slide9
OSFM TIPS & TRICKS
  • Supervisor Workbench versus Move form
    • Move form faster for playing specific job moves.
slide10
OSFM TIPS & TRICKS
  • Partial Move Behavior
    • Move quantity retains mother lot name (not updateable) instead of default child lot name. This is mismatch to real world lot naming as move quantity is usually the child lot.
slide11
OSFM TIPS & TRICKS
  • Lot Create Work Order default lot name
    • Default lot name assumes a split. If using full lot drop the suffix.
slide12
OSFM TIPS & TRICKS
  • Recommended Custom Reports:
    • Work Order Location for all released jobs
    • Actual yield versus estimated yield by job and part number.
slide13
Suggested Enhancements
  • Sub-lots: Use for die parts
    • Enables user to track good die by wafer in die bank. Each wafer is a die sub-lot. User selects sub-lots when selecting lots and lot create form accumulates quantities into the child lot. Today user cannot track good die by wafer unless treating each wafer as a separate lot (not feasible due to volume).
  • Co-products
    • Enable user to enter co-products and %’s for bills created via bill of material form.
  • Lot Create:
    • Default mother lot number into resulting lot field.
    • Add default split lot extension if user enters a quantity less than full lot (add extension when user tabs from quantity field)
slide14
Suggested Enhancements
  • Genealogy network (source and where used)
    • Explode with single select
slide15
Vendor mapping to OSFM

Options

  • Single inventory organization for all vendors
  • One Inventory organization per vendor
  • Hybrid:
    • Separate inventory organizations for major vendors
    • Single inventory organization for smaller volume vendors
slide16
Mapping subcontractors to OSFM
  • Single inventory organization for all vendors
    • Represent vendors via subinventory names to represent vendor / product stage
    • Setup an intransit subinventory to track lots moving between vendors
    • + for monthly close
      • One inventory organization to close
    • + for reporting: all lots on one shop floor
    • - For Advance Supply Chain Planning
      • Sourcing rules apply to inventory organizations so ASCP cannot recommend vendors via sourcing rules
      • Excludes product transit time among vendors
      • Limits resource capacity planning in network routings
slide17
Mapping subcontractors to OSFM
  • Separate inventory organizations for each vendor
    • Subinventories represent product stage by vendor
    • - for product costs (more complex roll-up)
    • - for monthly close (multiple organizations to close)
    • + for Advanced supply chain planning
      • Sourcing rules for vendor inventory organization
      • Explicit transit times
      • Vendor specific resource capacity planning
slide18
Business to Business Communications

B2B

Subcontractor manufacturing event communication and processing into Oracle purchasing, inventory, and OSFM application modules

slide19
B2B Process Outline
  • Collecting vendor event data
  • Vendor event database
  • Vendor event processing
  • Vendor B2B performance measurement
  • Backup Processes
  • Vendor bring-up for manual and automated reporting
  • B2B Project suggestions
slide20
B2B Process Outline…
  • Collecting vendor event data…
    • Define stages and events within each stage by product line
    • Define product lines: Product line scope:
      • same stage sequence
      • same events within each stage
    • Define stage and event matrix
    • Define event data elements
      • Oracle transaction data elements
      • B2B data elements
slide21
B2B Process Outline…
  • Collecting vendor event data…

Sample Stage and Event Matrix

slide22
B2B Process Outline…
  • Collecting vendor event data…
    • Define data elements for each stage and event combination
slide23
B2B Process Outline…
  • Collecting vendor event data…

Stage and event example: SHIP at FAB

EVENT CODE

SHIP

Vendor ID

This field represents the Partner’s DUNS number and needs to be reported by every partner.

Vendor Location ID

This field represents the Location DUNS number for Vendor Site location at which the respective manufacturing stage is being processed.

To Vendor ID

This field represents the ship-to vendor’s Location DUNS number.

slide24
B2B Process Outline…
  • Collecting vendor event data…

SHIP at FAB: Stage and event Example continued…

Transaction ID

Vendors need to report a transaction identifier that will be unique for all the events that are being reported by the vendor. This field eliminates confusion between user and vendor when errors occur with a transaction.

Transaction Date and Time

Vendors need to report all the transactions in GMT time and in 24 hr format. Code the value as per xml format ‘YYYYMMDDThhmmssZ’.

Part Number

This field represents a user part number being purchased as per PO line provided to the FAB vendor .

Manufacturer Part Number:

This field represents the FAB part number assigned by the Wafer Foundry that cross references to the user part number.

slide25
B2B Process Outline…
  • Collecting vendor event data…

SHIP at FAB: Stage and event Example continued…

Lot Stage Identifier

This field represents physical location of the lot in the manufacturing cycle. This is a hardcoded field and needs to be reported as “FAB” all the time for all transactions being reported as shipment from the FAB vendors.

Lot Type Classification

This field represents the classification of the Lot and has two possible choices,

Engineering

Production

This is needed if vendors cannot omit engineering lots from reporting.

Lot Number

This field represents the FAB assigned lot number to the lot that is being shipped by the FAB vendor. Each event requires a unique lot number. Do not report the same part number, lot number for multiple shipments.

slide26
B2B Process Outline…
  • Collecting vendor event data…

SHIP at FAB: Stage and event Example continued…

Lot Quantity

This field represents the full lot quantity being shipped for the purchased part number

PO Number

This field represents the NetLogic PO number for the purchased wafer. and lot

PO Line Number (optional)

This field represents the NetLogic assigned PO Line number for the purchased part number and lot. Note: automation will be easier if the FAB vendor can supply the PO line number in addition to the PO number.

REPEAT FOR ALL PRODUCT LINE STAGE/EVENTS

slide27
B2B Process Outline…
  • Collecting vendor event data…
  • Generate vendor reporting requirements document to include:
    • Reporting rules by stage
    • Stage and event data elements with explicit definitions
    • Provide spreadsheet event samples
slide28
B2B Process Outline…
  • Collecting vendor event data…
  • Generate Network Routing Flow document
    • Routing flow for each product line and stage
      • Enables vendors to map their routings to OSFM network routings
      • Multiple vendor operations may occur for each OSFM operation
      • OSFM operations are based on pay points and product lot tracking requirements (lot location and lead times)
slide29
B2B Process Outline…
  • Collecting vendor event data…
  • Generate vendor communications bring up document:
    • Manual reporting
    • Automated reporting
slide30
B2B Process Outline…
  • Collecting vendor event data…
  • Manual Reporting
    • Require event reporting that builds foundation for and eases transition to automated reporting
    • Do not derive Oracle application transactions from vendor snapshots (shop floor picture or lot location report)
      • Error prone
      • User accepts ownership for playing the correct transaction rather than the vendor accepting responsibility to report correct event data and sequence
slide31
B2B Process Outline…
  • Collecting vendor event data…
  • Select data collection process and event data format and language
  • Data Collection Process Options
    • File Transfer Protocol (FTP) or secure FTP
      • Vendor places file on a server
      • User retrieves the file from the server
    • B2B Software (Web Services) TIBCO, BEA, IBM, etc.
      • Vendor communicates specific data package
      • B2B software authenticates, validates, and passes event to a B2B database
slide32
B2B Process Outline…
  • Collecting vendor event data…
  • Event Data Formats and language
    • .CSV files, comma delimited flat files matching user proscribed format and text language
    • RosettaNet Partner Interface Process (PIP) by mapping event data elements to pre-defined columns for a PIP event (7B1) Distribute WIP
      • Each PIP specification includes a business document and a detailed business process that includes interaction, data transmission, security and error-handling requirements.
      • Language: usually XML
slide33
B2B Process Outline…
  • Collecting vendor event data…
  • Data Formats and language
    • Extensible Markup Language (XML)
      • XML was designed to describe data and to focus on what data is.
      • The Main Difference Between XML and HTML
      • XML was designed to carry data.
      • XML is not a replacement for HTML.XML and HTML were designed with different goals:
      • XML was designed to describe data and to focus on what data is.HTML was designed to display data and to focus on how data looks.
      • HTML is about displaying information, while XML is about describing information.
slide34
B2B Process Outline
  • Collecting vendor event data…
  • XML Example:
    • <note>
    • <to>Tove</to>
    • <from>Jani</from> <heading>Reminder</heading>
    • <body>Don't forget me this weekend!</body> </note>
    • The note has a header and a message body. It also has sender and receiver information. But still, this XML document does not DO anything. It is just pure information wrapped in XML tags. Someone must write a piece of software to send, receive or display it.
slide35
B2B Process Outline…
  • Collecting vendor event data…
  • Data Formats
    • RosettaNet 7B1
    • Simple Object Access Protocol (SOAP) 1.1
      • XML based protocol that consists of three parts: an envelope that defines a framework for describing what is in a message and how to process it, a set of encoding rules for expressing instances of application-defined datatypes, and a convention for representing remote procedure calls and responses.
    • ebXML Business Process Specification Schema (BPSS) ebXML
      • (Electronic Business using eXtensible Markup Language), is a modular suite of specifications that enables enterprises of any size and in any geographical location to conduct business over the Internet.
slide36
B2B Process Outline…
  • Collecting vendor event data…
  • Generate a trading partner agreement (TPA) with each vendor.
    • Communication process (FTP, Web Service, etc.)
    • Event content
    • Communication frequency (daily, per shift, etc.)
    • Error Handling
      • Level 1: format
      • Level 2: content
    • Vendor bring up and certification process
slide37
B2B Process Outline…

2. Vendor event database

  • Event Processing
    • Level 1 Validation of vendor events
        • File Format
        • Data file uniqueness
        • File Parsing (corrupt data)
        • Successful insert to vendor data base
        • Send response to vendor for each vendor transmitted file
slide38
B2B Process Outline

2. Vendor event database…

  • Event storage
    • Convert vendor reported event into an input record for the vendor database.
    • Insert vendor reported events into a common database independent of the manner in which vendors reported the event. This is often referred to as a canonical database.
slide39
B2B Process Outline…

2. Vendor event database…

  • Event storage…continued
    • Store events as reported but enable error correction process to change event data elements PRIOR to generating and uploading Oracle applications transactions.
    • Generally vendors resend events for level 1 errors only
    • Vendors resend events with new transaction ID’S for a level 2 (content) errors.
slide40
B2B Process Outline…

2.Vendor event database…

  • Maintain event status codes (details in next section)
  • Event archive and purge: Provide process to archive data and reduce active database size.
slide41
B2B Process Outline…

3.Vendor event processing

  • Event status: Maintain vendor reported event processing status codes per event
    • New: Loaded into vendor data base
    • Error: Data content (based on level 2 validation)
    • Pending: Event is out of sequence based on Product line, stage, and event pre-defined matrices
    • Ready for Upload to Oracle applications
    • Error: Upload error in Oracle open interface
    • Successful Upload: Loaded successfully through open interface into Oracle application
slide42
B2B Process Outline…

3.Vendor event processing…

  • Error Checking: Design Level 2 (content) validation to ensure generated Oracle applications transactions will process successfully through Oracle application open interface tables.
  • Design level 2 error checks by product line, stage, and event. (samples follow)
slide43
B2B Process Outline…

3. Vendor event processing…

  • Receipt
    • Validate correct event sequence (check last successful event and pre-defined event sequence table)
    • Valid part#/Lot#/Quantity
    • Correct vendor mapping ( INV ORG and vendor subinventory mapping)
    • Report lot attributes if required at reported stage
slide44
B2B Process Outline…

3. Vendor event processing…

  • Split/Merge processing
    • Validate correct event sequence (check last successful event and pre-defined event sequence table)
    • Valid part#/Lot#/Quantity
    • Required fields available
    • Meets pre-defined split and merge business rules
slide45
B2B Process Outline…

3. Vendor event processing…

  • Start: Work order start
    • Validate correct event sequence (check last successful event and pre-defined event sequence table)
    • Valid part#/Lot#/Quantity
    • Required fields available
    • Valid bill of material and routing
    • Valid component part#, lot, quantity, or component lots (multiple components)
    • Report lot attributes if required at reported stage
slide46
B2B Process Outline…

3. Vendor event processing…

  • Map events to Oracle transactions: Adaptor will generate appropriate Oracle transactions or series of transactions for successful event. Examples follow:
    • Receipt: Inventory receipt
    • Split: Inventory lot or work order lot split
    • Merge: Inventory lot or work order lot merge
    • Start: work order start
    • Move: work order move
    • Complete: work order move/complete
    • Ship: Inventory lot transfer or inter-org transfer
slide47
B2B Process Outline…

3. Vendor event processing…

  • Error correction process requirements
    • Track errors in the vendor event database by maintaining error codes and explanations
    • Link appropriate error code to vendor event records where errors are identified
slide48
B2B Process Outline…

3. Vendor event processing…

  • Error correction process requirements...continued
    • Develop user form based interface to:
      • Query errored events and enter data corrections. The goal is to correct errors rather then deleting records and having vendors resend. Each vendor input event is a unique transaction regardless of transaction data.
      • User resets event status code so that adaptor next run will recheck this event and if successful generate Oracle transaction and upload to Oracle applications
slide49
B2B Process Outline…

3. Vendor event processing…

  • Event sequencing requirements: Sequence events by maintaining correct predecessor event matrices for each product line and stage.
  • Where event does not match a correct predecessor place event in pending status
  • For some events multiple predecessor and successor events are possible.
  • Generate Oracle applications transactions for events that pass level 2 validation.
slide50
B2B Process Outline…

3. Vendor event processing…

  • Load transactions to Oracle interfaces
  • Identify errors in Oracle interface: Record data and remove errored records from Oracle open interfaces. Report errors so that users can correct input data or address and Oracle software based problem.
  • Event status changes: Update event status as event is processed into Oracle applications
slide51
B2B Process Outline…

4. Vendor B2B performance measurement

  • Generate reports that measure vendor reporting results
      • Timely reports
      • Accuracy by stage and event and part#.
      • Report comparing vendor system on hand balances and open work orders with Oracle application on-hand balances and open work orders.
slide52
B2B Process Outline…

5. Backup Processes

  • Vendor reporting: alternate reporting method if automated reporting is down. May be possible depending on volume
  • Vendor event processing if automated system is down for extended period. Playing transactions directly into Oracle applications.
  • Holding events when ERP system is down.
slide53
B2B Process Outline…

6. Vendor bring-up for manual and automated reporting

  • Key Documents for vendors
    • B2B MFG Vendor reporting requirements document
      • Reporting rules by stage and event
      • Event reporting details by stage and event
      • Event sample spreadsheet
    • User Product Routing flows
    • Vendor communications process
slide54
B2B Process Outline…

7. B2B Project suggestions

  • Vendors need to understand user part numbers, product structures, and network routings.
  • Vendors report user part numbers and lot numbers
  • Generate consistent reporting process across all vendors
  • Allow time for rigorous event testing
  • Parallel testing with real data is wise particularly if volume is high
  • Expect high error volume at first
  • Go live when you can correct errors within one day and..
    • Error correction is effective and fast
    • Vendors respond quickly to reported errors
slide55
B2B Process Outline
  • Contact Information
  • Jerry Edwards
  • jkedwards2002@hotmail.com
  • 650-799-6699