Shop Floor Manager (OSFM) and Business to Business - PowerPoint

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					Shop Floor Manager (OSFM) and
  Business to Business (B2B)
           Guidelines
         Jerry Edwards




                                1
Cowboy’s Guide to Life:

• The first thing to do when you get up in the
  morning is to put on your Stetson.

• The 2nd thing to do when you get up in the
  morning is to put on your boots.

• Talk low, talk slow, and don‟t say too much

• You don‟t need decorated words to make your
  meanin‟ clear. Say it plain and save some breath
  for breathin‟.

                                                 2
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 code to generate Oracle
  application transactions based on vendor
  reported events

                                                    3
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
                                                  4
Scope:
• OSFM Suggestions
  • Product structure
  • Network routing
  • Mapping subcontractors into OSFM
     • Single inventory organization for all
       vendors
     • Vendor specific inventory organizations

  • Business to Business (B2B) Functional
    Requirements
                                                 5
OSFM Product Structure Suggestions

• Separate part numbers for each stage
   • FAB/SORT/DIE/ASSEMLED DIE/TESTED
     DIE/FINISHED DIE


• Network routing scope:
  • start and complete work orders at the same
    vendor for a single part number (stage)
  • Keep routings simple
  • Define alternate rework paths if required
                                             6
  Mapping subcontractors to OSFM

• 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

                                                       7
  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 Advance Supply Chain Planning
      – Sourcing rules apply to inventory organizations
        so ASCP cannot recommend vendors via
        sourcing rules
      – Excludes product transit time among vendors
                                                       8
 Mapping subcontractors to OSFM

• Separate inventory organizations for each
  vendor
  •   Subinventories represent product stage
  •   - for product costs (more complex)
  •   - for monthly close (multiple organizations to close)
  •   + for Advanced supply chain planning
         – Sourcing rules for vendor inventory
           organization
         – Explicit transit times


                                                          9
Business to Business Communications
                B2B

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




                                               10
           B2B Process Outline

1. Collecting vendor event data
2. Vendor event database
3. Vendor event processing
4. Vendor B2B performance measurement
5. Backup Processes
6. Vendor bring-up for manual and automated
   reporting
7. B2B Project suggestions

                                              11
B2B Process Outline
1. Collecting vendor event data tasks


  • Define stages and events within each
    stage by product line

  • Define product lines: Product line scope:
    • same stage sequence
    • same events within each stage



                                                12
B2B Process Outline
1. Collecting vendor event data tasks


  • Define stage and event matrix

  • Define event data elements
    • Oracle transaction data elements
    • B2B data elements




                                         13
B2B Process Outline
1. Collecting vendor event data tasks
            Stage and Event Matrix




                                        14
B2B Process Outline
1. Collecting vendor event data tasks



  • Define data elements for each stage and
    event combination




                                              15
B2B Process Outline
1. Collecting vendor event data tasks
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.

                                                                      16
B2B Process Outline
1. Collecting vendor event data tasks
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 NetLogic 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 NetLogic Microsystems 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 Netlogic part number.


                                                                            17
B2B Process Outline
1. Collecting vendor event data tasks
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.


                                                                            18
B2B Process Outline
1. Collecting vendor event data tasks
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

                                                                              19
B2B Process Outline
1. Collecting vendor event data tasks

•   Generate vendor reporting requirements
    document to include:

    • Reporting rules by stage

    • Stage and event data elements with
      explicit definitions


                                             20
B2B Process Outline
1. Collecting vendor event data tasks

•    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 occur for
          each OSFM operation
       • OSFM operations are based on pay
          points and product status requirements
                                               21
B2B Process Outline
1. Collecting vendor event data tasks

•    Generate vendor communications bring up
     document:
    • Manual reporting
    • Automated reporting




                                               22
B2B Process Outline
1. Collecting vendor event data tasks

•    Manual Reporting
    • Require event reporting that builds
      foundation for automated reporting
    • Do not derive Oracle application
      transactions from vendor snapshots
      • Error prone
      • User accepts ownership for playing the
         correct transaction rather than the
         vendor accepting responsibility to
         report events in correct sequence
                                             23
B2B Process Outline
1. Collecting vendor event data tasks:
•   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
                                                    24
B2B Process Outline
1. 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
                                                          25
B2B Process Outline
1. Collecting vendor event data tasks
–    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.
                                                          26
B2B Process Outline
1. Collecting vendor event data tasks
•    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.
                                                       27
B2B Process Outline
1. Collecting vendor event data tasks
•    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.
                                                                  28
B2B Process Outline
1. Collecting vendor event data tasks

•    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
                                                         29
B2B Process Outline
1. Collecting vendor event data tasks

   If you‟re ridin‟ ahead of the herd, take a
    look back every now and then to make
    sure it‟s still there.

   Don‟t re-invent the wheel. Take
    advantage of existing software and
    standards.


                                                 30
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
             reported event




                                                    31
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.



                                                        32
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.



                                                  33
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.




                                                      34
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
                                                      35
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)




                                                      36
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



                                                         37
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




                                                       38
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
                                                         39
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
                                                         40
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




                                                         41
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
                                                      42
B2B Process Outline
3. Vendor event processing

  •   Event sequencing requirements: Sequence
      events by maintaining product line and stage
      allowed event sequence matrices. This is a key
      process.

  •   For some events multiple predecessor and
      successor events are possible.

  •   Generate Oracle applications transactions for
      events that pass level 2 validation.
                                                      43
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
                                                         44
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.
                                                       45
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.


                                                        46
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
      • User Product Routing flows
      • Vendor communications process




                                                   47
B2B Process Outline
 7. B2B Project suggestions
• Vendors understand user part numbers, product
    structures, and network routings
• Generate consistent reporting process across all
    vendors
• Allow time for rigorous testing of all events
•    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
    • Error correction is effective
    • Vendors respond quickly to reported errors
                                                               48
B2B Process Outline



•   Makin‟ it in B2B is kinda like bustin‟ broncs:
    your gonna get thrown a lot. The simple
    secret is to keep getting‟ back on.




                                                     49
B2B Process Outline



•   Contact Information
•   Jerry Edwards
•   jkedwards2002@hotmail.com
•   650-799-6699




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