Transcript Document 7825707

OAC
OSFM and a
Manufacturing Execution System:
Compatible Partners
Training Day
January 17, 2007
Objectives
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Outline the mechanics of PI’s interface project
Communicate the challenges encountered
Discuss the solution components employed
Share some tips and pitfalls
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Date: January 17, 2007
Agenda
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Introduction - Power Integrations
Background on the Project
Overview of PI Supply Chain
Overview of OSFM Integration
Challenges and Considerations
Interface Components
Lessons Learned
Questions and Answers
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Date: January 17, 2007
Power Integrations
Innovation in Power Conversion
 Fabless Semiconductor Manufacturer
 Headquartered in San Jose
 Founded in 1988
 Leading supplier of high-voltage analog integrated circuits
(ICs) used in power conversion.
– Enable compact, lightweight power supplies that are simpler to
design and manufacture, more reliable, and more energy-efficient
than those made with competing technologies.
– Power a vast range of consumer and industrial electronics—
computers, DVD players, TV set-top boxes, cell phone chargers,
home appliances, telecom networking equipment, and many
others.
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Date: January 17, 2007
Project Background – Business Considerations
Issues:
 Camstar MESA used for tracking production only
 WIP/Inv Cost – done on massive spreadsheets
 Extraordinarily long and painful month end close
Solution:
 Implement OSFM & Inventory to manage WIP
valuation
– In process Sort, Assembly, Test, Tape & Reel, etc
– Wafer Bank, Die Bank, Untested, etc
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Project Background - Timetable
Upgrade to 11.5.10
from 11.0.3
• Order Management
• Inventory
• Purchasing
• Financials (GL/AP/AR/CM/FA)
• Human Resources
Develop interface
engine (eFabless)
Install interface engine,
develop and test interfaces
• Receiving
• Inventory
• OSFM
Replace Spreadsheet Cost
Accounting with OSFM
2006
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2007
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Date: January 17, 2007
Overview – Supply Chain
OFFSHORE
SUBCONTRACTORS
WFR
BANK
DIE
BANK
ASSY
UN
TESTED
HONG KONG
DISTRIBUTION
TEST (& VA)
FG
FG
Wafer Dlvd
from Fab
UN
BAKED
WFR
BANK
BAKE + BAG
UN
TESTED
SORT
TEST
BAKE + T&R
DIE
BANK
FG
TEST + LF
SAN JOSE
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Date: January 17, 2007
OSFM Integration
MESA
Mesa-to
OSFM
Interface
Standard Costs
Cost Rolls
Bills of
Material
Cost
Management
OSP
Receipts
Shop Floor
Management
Expected Yields
Absorption Rates Lot-based Jobs
BOMs
Routings
Departments
Resources
Assets
(WIP Value)
Variances
OSP
Requisitions
Wafer
Die
Untested
Unbaked
Finished Goods
Wafer
Receipts
Purchasing
Wafer POs
OSP Blanket Orders
OSP Blanket Releases
Variances (PPV)
Inventory
Items,UOM,
QOH
General
Ledger
Assets @ Standard Cost
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Date: January 17, 2007
Challenges and Considerations
 MESA uses single item number for multiple
operations:
– Wafer number for Wafer Bank, Sort, and Die Bank
– FG number for Assembly, Test, and Finished Goods
 Multiple Organizations with changes in inventory
asset ownership
 Not every transaction in MESA is necessary for
Cost Accounting
 Must avoid prematurely processing a
“downstream” transaction for a given lot before
“upstream” transaction is successfully played
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Components – Getting Started - Tables
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Components – Getting Started - Columns
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Components – Simplified Overview
AS400
eFabless Engine
Write Data to
Oracle
Rules and
Lookups
MESA
Transactions
Get Data from
MESA
Selected
Transactions
Read Results
from Oracle
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Oracle
Metered by Lot &
Control Number
Receiving
OSFM
Inventory
Success or Failure
Date: January 17, 2007
Components – Example of Transactions
MESA
MOVE,NOT
INTFCD to OSFM
Wafer Dlvd
from Fab
Physically
arrives in
San Jose
ORACLE
SAN JOSE
ORGANIZATION
ORACLE
OFFSHORE
ORGANIZATION
STRT
NorCal OAUG Training Day
2000
WAFER
RECVG
1
P.O. Rcpt /
Deliver
2100
MOVE WAFER
ACCPT
2200
QC
MOVE, SPLIT, CONV NOT
INTERFACED to OSFM
2300
2400
2450
MOVE WAFER WAFER
WS
QUE
SORT STAGE
2475
QC
STAGE
2500
WS
QC
MOVE
2900
DIE
BANK
WAFER
BANK
UM = WFR
16
Interorg
Transfer
WAFER
BANK
UM = WFR
4
Job Start
Mode 2
LBR
+OH
UM = DIE
7
Lot Move
and
Completn
DIE BANK
SORT
UM = DIE
YIELD %
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Components – Example of Transactions
MOVE,SHIP NOT
INTFCD to OSFM
MESA
2900
DIE
BANK
2950
DIE
STAGE
3000
ASSY
(POWR)
RECV, MOVE NOT
INTFCD to OSFM
IN
RECV
TRNST
3000
ASSY
SHIP
(PIC2)
IN
TRNST
4000
UN
TESTD
OSP
Std’s
4
Job Start
Mode 2
ORACLE
OFFSHORE
ORGANIZATION
3500
ASSY
RECV
7
Lot Move
and
Completn
UM = EA
DIE BANK
UNTESTED
ASSEMBLY
UM = DIE
UM = EA
16
Interorg
Transfer
YIELD %
OSP
Blanket PO
Receipt /
Deliver
OSP
OSP
Req
17
P.O. Rcpt / Qty = Outs
Deliver
ORACLE
SAN JOSE
ORG
OSP
Release
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16
Interorg
Transfer
DIE BANK
UM = DIE
Ownership
retained in the
U.S. until receipt
offshore
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UNTESTED
UM = EA
Ownership
transferred at time
of shipment to the
U.S.
Date: January 17, 2007
Lessons Learned
 API user guides are not always clear
for example…
– Initially used rcv_lots_interface for Receiving Deliver
– Learned via TAR should be mtl_transaction_lots_interface
 TRM Column descriptions are not always clear
for example…
– Column Name = PRODUCT_CODE
– TRM description = Stores the product name to identify the
source transaction for the record
– Mandatory = No
– Discovered it is required for Receiving Delivery (RCV)
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Date: January 17, 2007
Lessons Learned
 Error messages are not always accurate
for example…
– RCV_TP_ACCT_PERIOD_CLOSED error caused by
values unrelated to accounting periods.
– Transactions set to ERROR status with no error message
 Mapping the right rules and data values took longer
than expected.
 Need to be on the latest patchset
 Recognize the need to properly staff for on-going
monitoring of the transactions
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Date: January 17, 2007
Questions and Answers
Presenter Contact Information
Clark Stockard
(408) 414-8879
[email protected]
Travis Cox
(925) 786-1230
[email protected]
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Appendix – Example of eFabless Rule
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Appendix – Example of eFabless Rule
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Appendix – Example of eFabless Rule
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Appendix – Example of eFabless Rule
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Appendix – Example of eFabless Rule
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Date: January 17, 2007