Oracle R12 Applications

Bills of Material

TCS Internal

Topics

Glossary (Related Business Terminology)

General Introduction to Bill of Material

Integration with other Modules

Setups

Run Through of End to End Business Processes

Standard Reports & Online Inquires

BOM Tables , APIs/Interfaces

Sample Process Analysis Questions

April 16, 2015

Glossary (Related Business Terminology)

April 16, 2015

Glossary (Related Business Terminology)

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

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

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

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

Work day Calendar

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

April 16, 2015

Glossary (Related Business Terminology)

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

Option Class BOM

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

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

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

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

April 16, 2015

General Introduction to Bill of Material

April 16, 2015

Module Overview
Bills
By what (components) ?
By how much (component quantity) ?
From where (component replenishment
info) ?

Routings

In what way (operations) ?

Who (resources) ?
How long (manufacturing lead time) ?

Maintains workday calendars

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

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Workday Calendar

Workday
Calendar

MPS/MRP

WIP

Inventory

BOM

CRP

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Type of Bills
Computer
Planning Bill
Model
Item

Desktop (80%)

Laptop (20%)

Model Bill

256MB RAM

Monitor

Option
Class Bill

Option
Class Item
Standard Bill

Picture Tube

16

17

Cabinet

Option

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Resource

Warehouse
Space

Available
workdays

Available
hours

Shop Floor

Shift A
Workday Calendar

Worker

Shift
times

Machine
department

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Routings

New product
design

New product
BOM

Routing

Engineering

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Indented Bill
A

C
B
C

Qty = 1
Unit Cost =
$7
Qty = 2

D
E

Qty = 2
Unit Cost =
$5
Qty = 3
Unit Cost = $4

Single Level Bills

Unit Cost = $51

Final Level
Rolled up Cost

Qty = 2
Unit Cost = $22

Qty = 2
Unit Cost =
$5

Qty = 3
Unit Cost = $4

Qty = 1
Unit Cost = $7

1st Level
Rolled up Cost

Indented Bill

April 16, 2015

General Introduction- Oracle Bill of Materials

April 16, 2015

Alternate Bill & Alternate Routing

Primary Way of manufacturing CRANK SHAFT
CRANK SHAFT

BILLET

DIE

SAND

Operations:
10. Heating , 20. Hammering , 30. Forging , 40. Twisting , 50. Heat
Treatment
Alternate Way of manufacturing CRANK SHAFT
CRANK SHAFT

MOLTEN METAL

Alternate Bill: CASTING

CHEMICAL

MOULD

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

Alternate Routing: CASTING

April 16, 2015

General Introduction- Oracle Bill of Materials

Oracle Bill Of Materials covers these major Functions as a part of
Discrete Manufacturing:
Creating and Maintaining Routings
Creating and Maintaining BOM
Defining and Maintaining Lead Times
Manufacturing Scheduling
Oracle E-Records

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Integration with other Modules

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16

Integration with Other Modules

Model and Configurations

OrderOracle Cost
Managemen
Management
t

Manufacturing BOM

Work in
Oracle
WIP
Process

Bill of
Materials

Engineering
ECO (Engg Change Orders)

Oracle
Inventory

Inventory
Items

MRP
Planning BOM

Purchasing
Outside Processing

Costing
Cost Rollups

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Setups

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18

BOM Parameters

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

Inactive Status: De-activate Configurations program uses this item status for the configured items
Numbering Segment: The numbering segment defined in the OE Validation Org will be used for the
configured items.
Numbering Method: This is used for assigning the unique number for the configured items. There are
various logics used for numbering method. Click on

Icon

to know more about it.

Create Lower Level Supply: This setup decides the supply creation of lower level Configurations or ATO
Items. Selecting NO will only create supply for the Top level configuration items.
Config BOM Creation Allowed: Enable this in all the organizations where you manufacture or purchase your
configurations.
Use Phantom Routings: If checked will include phantom routing components, resources and Overheads in
the top level assembly. Else only the components are included.
Inherit Phantom Op Seq: Enabling this will inherit op. sequence of their parent assemblies. Else they
maintain their own sequences.
April 16, 2015

Define and Build Work Day Calendar

(Required)

(N) Bom>Setup>Calendar

(B) >Workday Pattern

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

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Define and Build Work Day Calendar

(Required)

(N)
Bom>Setup>Calendar>Shifts
Define the shifts as per the business requirements.

(B) Times

There can be multiple shift and each shift can have a start and stop time.

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Define and Build Work Day Calendar

(Required)

(N)
BOM>Setup>Calendar>Dates

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Define Exception Template (Optional)

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

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

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

Every time when a calendar is defined or modified, make sure it is Build to bring the changes
in to effect.
! System will throw a note on this

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Define Resources (Optional)

(N): BOM> Routing>Resource

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Define Resources (Optional)

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

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Define Resources (Optional)

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

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Define Departments (Optional)

(N): BOM> Routing> Departments

April 16, 2015

Define Departments (Optional)

(N): BOM> Routing> Departments

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Define Profile Options (Required)

(N) Sys Admin>Profiles>Personal

Profiles
>Query by BOM%

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Run Through of End to End Business

Processes

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32

Define Routings

(N) Navigation: BOM>Routings>Routings

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

(N) Navigation: BOM>Routings>Routings

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Define Routings

The Date from which this

routing operation is in
effect.

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Define Routings

Define which operations in a routing record move transactions by defining how resources are consumed
at that operation.
The Count Point and Autocharge check boxes work together.
The Count Point and Autocharge check boxes can be set to either on or off.
However, you cannot set Count Point on and Autocharge off.
When you move assemblies from an operation with Count Point on / Autocharge on operation to another
count point operation set the same way, Work in Process automatically completes all Count Point off /
Autocharge on count point operations between them.
To transact a Count Point off / Autocharge off count point operation, you must explicitly move assemblies
into and out of that operation. Moving assemblies past a Count Point off / Autocharge off count point
operation acts as though the operation did not exist in the routing.
This is particularly useful for rework or debug operations that are performed on a portion of the
April 16, 2015
assemblies you process.
3

Define Routings

Define your Operation

Yield. 100% yield is
represented as 1

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Define Routings

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

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Define Routings

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

Some of the additional functions which can be accessed from BOM Screen include:
Rollup Cost, Compute Lead Time, Rollup Lead time, Std Operations, Departments, BOM,
Indented BOM etc
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Define Routings
(N) Navigation: BOM>Routings>Routings Details

Define your completion sub inventory and

locator. This will default in the assembly
completion transactions for the
Completion sub inventory.
April 16, 2015

Define Routings

(N) Navigation: BOM>Routings>Operation Resources

You can associate multiple resources with an operation on a routing. For each resource, you can
determine if you want to include that resource in scheduling and lead time calculations. You can also
collect costs for a resource on a routing if you specified the resource as a costed resource.
Define your operation timings in the Usage Rate or Amount based on the basis. A basis of Item indicates
when your charges fluctuate with quantity change. Lot Indicates resource usage quantity is the amount
required per job (Setup Charges).
Set your scheduling options as either Yes or Prior or Next or No. Based on this, the operation will be
either scheduled or scheduled prior to this operation or scheduled next to this operation.
April 16, 2015

Define Routings

(N) Navigation: BOM>Routings>Standard Operations

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

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

April 16, 2015

Define BOM
(N) Navigation: BOM>BOM

Click here to
know more

April 16, 2015

Define BOM
Click here to

go back
BOM Field
References
Operation Sequence: Assign your routing operation sequence on this Op.seq to assign your item to

the specific operation. This is used for Backflush transactions.

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

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BOM Fixed Component

Benefits
Usage

Support for materials having fixed usage irrespective of the job size for discrete WIP job, OSFM lotbased jobs or Flow manufacturing

Accurate valuation of assembly cost where fixed quantities of materials are used for a job

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

April 16, 2015

Common BOM

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

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

April 16, 2015

Define BOM
Many options available from Tools menu
Create Common Bill
Check for Loops
Rollup Costs
Rollup Lead Times
..

(N) Navigation: BOM>BOM>

Tools

April 16, 2015

Substitute

(N) Navigation:
BOM>BOM>
Substitute

You can assign any number of substitute items to each bill component and you can assign
the same substitute item to more than one component. The substitute item quantity is the
quantity needed to replace the full component quantity. The quantity can differ from the
component usage quantity.
Planning bills and model, option class, and planning components cannot have substitute
components.
April 16, 2015

Reference Designators

(N) Navigation: BOM>BOM> Designators

Reference designators are sequenced comments and instructions that pertain to a

component. For example, you may have drawings that clarify the assembly process for
certain components, or further instructions for the use of a large quantity of the same
component. You can specify whether to assign one reference designator for every usage of
the component or assign any number of reference designators to the component.
Planning bills and model, option class, and planning components cannot have reference
designators.
April 16, 2015

BOM Attachments

(N) Navigation: BOM>BOM> Attachments

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

You can attach text and files, such as spreadsheets, graphics, and OLE objects to bills of
material, engineering change orders, routings, routing revisions, and routing operations.
For example, an attached file may include comments, such as a graphical representation
of the bill structure, or detailed instructions and schematic diagrams for routing
operations.
April 16, 2015

Defining and Maintaining Lead Times

Assembly : Make
Processing
Lead time

SubAssembly : Make
Cumulative Manufacturing
Lead time

Component : Buy
Cumulative Total
Lead time

Preprocessing Lead time

Processing Lead time
Postprocessing Lead time

Cumulative manufacturing lead time =

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

April 16, 2015

Defining and Maintaining Lead Times

Dynamic Manufacturing Lead

Time
Oracle Engineering computes the fixed and variable portions of manufacturing

(processing) lead time using routings and detailed scheduling

Calculating processing lead time for manufactured items
Fixed lead time
Variable lead time

April 16, 2015

Defining and Maintaining Lead Times

April 16, 2015

Defining and Maintaining Lead Times

April 16, 2015

Defining and Maintaining Lead Times

April 16, 2015

Defining and Maintaining Lead Times

Result of
Lead Time
Roll Up

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Calculate Manufacturing Lead Times

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Manufacturing Scheduling

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Manufacturing Scheduling

April 16, 2015

Manufacturing Scheduling

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Detailed Scheduling
Job Start
date / time
Op Seq 10
Res Seq 1

Res Seq 2

Res Seq 2

Op Seq 20
Res Seq 1

Res Seq 3

Res Seq 4

Op Seq 30
Res Seq 1

Res Seq 2

Scheduled = Yes
Scheduled = Next
Scheduled = Prior

Job
Completion
date / time

Scheduled = No

April 16, 2015

E- Records
Overview of Electronic Signature (e-signature) on Electronic Records (e-Records)
The Food and Drug Administration (FDA) issues new regulations for Quality Systems using
computerized software in the FDA code of Federal Regulations (CFR) Title 21 Part 11.
In general, 21 CFR Part 11 describes the requirements that must be met when using e-records and esignatures but does not describe where they are required. They are left to the discretion of medical
device manufacturers as where to use e-records and which e-signature to be used.
(More details are covered in the Oracle E- Records Implementation Guide).

April 16, 2015

E- Records
CFR Part 11 and Oracle Bill of Materials
E-records and E-signatures for Oracle Bills of Material
The following table lists the Oracle Bills of Material events seeded in Oracle ERecords.
EVENT

Online or Deferred E-Signature

E-Record Includes Attachment

Bill Creation

Online

Yes

Bill Update

Online

Yes

Routing Creation

Online

Yes

Routing Update

Online

Yes

Mass Change Bills

Online

No

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Standard Reports & Online Inquires

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64

Indented Bills Find Indented Bills

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Indented Bills - View

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Item Where Used

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Bill Comparison

April 16, 2015

Bill Comparison

April 16, 2015

Standard Reports

Bill of Material Comparison

Report

Bill of Material Listing Report

Bill of Material Loop Report

Bill of Material Structure

Report

Bill of Material Parameter

Report

Consolidated Bill of Material

Report

Delete Items Report

Department Report

Item where used Report

Resource Report

Resource Where used Report

Routing Report

Standard Operation Report

Workday exception sets

Report

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BOM Tables , APIs/Interfaces

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71

Base Tables - Oracle Bill of Materials

BOM_CALENDARS

BOM_CALENDAR_DATES

BOM_CALENDAR_EXCEPTIONS

BOM_PARAMETERS

BOM_DEPARTMENTS

BOM_RESOURCES

BOM_STRUCTURES_B

BOM_COMPONENTS_B

BOM_COMPONENT_OPERATIONS

BOM_OPERATION_RESOURCES

April 16, 2015

ERD - BOM
MTL_SYSTEM_ITEMS_B
#INVENTORY_ITEM_ID
#ORGANIZATION_ID

BOM_BILL_OF_MATERIAL
S
#BILL_SEQUENCE_ID

BOM_INVENTORY_COMPONEN
TS
#COMPONENT_SEQUENCE_ID
BOM_OPERATIONAL_ROUTING
S
#ROUTING_SEQUENCE_ID
BOM_OPERATION_SEQUENCES
#OPERATION_SEQUENCE_ID
BOM_OPERATION_RESOURC
ES
#OPERATION_SEQUENCE_ID
#RESOURCE_SEQ_NUM

April 16, 2015

ERD - Calendar
BOM_WORKDAY_PATTERNS
#CALENDAR_CODE
#SHIFT_NUM

BOM_CALENDAR_EXCEPTIONS
# CALENDAR_CODE
# EXCEPTION_SET_ID

Other Important tables

BOM_CAL_WEEK_START_DAT
ES
BOM_CAL_YEAR_START_DAT
ES

BOM_CALENDARS
#CALENDAR_CODE

BOM_CALENDAR_DATES
#CALENDAR_DATE
#CALENDAR_CODE
#EXCEPTION_SET_ID

BOM_CALENDAR_SHIFT
S
#CALENDAR_CODE
#SHIFT_NUM

BOM_SHIFT_DATES
#CALENDAR_CODE
#EXCEPTION_SET_ID
#SHIFT_DATE
#SHIFT_NUM

April 16, 2015

Interfaces / API - Oracle Bill of Materials

Interface Tables

BOM_BILL_OF_MATERIALS_INTERFACE

BOM_COMPONENT_OPS_INTERFACE

BOM_INVENTORY_COMPONENTS_INTERFACE

BOM_OP_RESOURCES_INTERFACE

APIs

BILL OF MATERIAL API

(Package = BOM_BO_PUB, Procedure = Process_BOM)
ROUTING API
(Package = BOM_Rtg_PUB, Procedure = Process_Rtg)

April 16, 2015

Sample Process Analysis Questions

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76

Sample Process Analysis Questions

1.

How do you maintain your BOM Data?

2.

How many levels of BOM do you currently have?

3.

How do you validate you BOM data?

4.

How do you handle your BOM Changes?

5.

How is your operations defined?

6.

How do you validate you lead times?

7.

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

8.

How does you product structure look like?

9.

Is your Final Assembly demand derived based on business

strategy?

10. Do you share your resources between departments?

11. How many shifts does your business work?
12. Do you have your holiday list?
April 16, 2015

A Simple Representation of a MODEL BOM

SCENARIO: Assembling a Computer to Customer Needs
Model = Desktop Computer
Total Levels = 3 (This is just an example)
Level 1:

April 16, 2015

A Simple Representation of a MODEL BOM

LEVEL 2:

April 16, 2015

A Simple Representation of a MODEL BOM

Assumptions & Explanation for Level 2:
Assumptions:

CPU is a Mandatory Item along with every computer

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

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

Explanations:

CPU Not choosing Optional and Mutually exclusive, makes it mandatory

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

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

since only one model can be selected if agreed to buy, Mutually exclusive
check box is selected so that it with Joy stick is selected, the other
becomes inactive.

Monitor and Mouse Since this is mandatory along with computer, optional
box is unchecked and since he has to choose either or the other, mutually
exclusive is checked.

April 16, 2015

A Simple Representation of a MODEL BOM

LEVEL 3:

April 16, 2015

A Simple Representation of a MODEL BOM

Explanation for Level 3:

Monitor and Mouse are optional items, the various makes of these
components are marked as Optional.

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

Manufactured Finished goods.

This BOM can further grow based on the customer requirements, but made short for
understanding purpose. This is just an example and help you model your actual
business requirements using these combinations.

THIS IS NOT AN END..BUT JUST A BEGINNING

April 16, 2015

Questions?

April 16, 2015

End Of Presentation

TCS Internal