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

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

• Jerry Edwards

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• Cowboys 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 dont say too much
• You dont need decorated words to make your
  meanin clear. Say it plain and save some breath
  for breathin.

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• 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

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• 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

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• 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

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• 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

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• 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

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• 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

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• 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

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• Business to Business Communications
• B2B
• Subcontractor manufacturing event
  communication and processing into Oracle
  purchasing, inventory, and OSFM application
  modules

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• 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

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• B2B Process Outline
• 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

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• B2B Process Outline
• Collecting vendor event data tasks
• Define stage and event matrix
• Define event data elements
• Oracle transaction data elements
• B2B data elements

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• B2B Process Outline
• Collecting vendor event data tasks
• Stage and Event Matrix

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• B2B Process Outline
• Collecting vendor event data tasks
• Define data elements for each stage and event
  combination

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• B2B Process Outline
• Collecting vendor event data tasks
• Stage and event example SHIP at FAB
• EVENT CODE
• SHIP
• Vendor ID
• This field represents the Partners 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 vendors
  Location DUNS number.

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• B2B Process Outline
• 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.

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• B2B Process Outline
• 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.

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• B2B Process Outline
• 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

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• B2B Process Outline
• Collecting vendor event data tasks
• Generate vendor reporting requirements document
  to include
• Reporting rules by stage
• Stage and event data elements with explicit
  definitions

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• B2B Process Outline
• 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

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• B2B Process Outline
• Collecting vendor event data tasks
• Generate vendor communications bring up document
• Manual reporting
• Automated reporting

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• B2B Process Outline
• 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

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• B2B Process Outline
• 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

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• 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

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• B2B Process Outline
• 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.

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• B2B Process Outline
• Collecting vendor event data tasks
• XML Example
• ltnotegt
• lttogtTovelt/togt
• ltfromgtJanilt/fromgt ltheadinggtReminderlt/headinggt
• ltbodygtDon't forget me this weekend!lt/bodygt
  lt/notegt
• 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.

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• B2B Process Outline
• 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.

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• B2B Process Outline
• 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

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• B2B Process Outline
• Collecting vendor event data tasks
• If youre ridin ahead of the herd, take a look
  back every now and then to make sure its still
  there.
• Dont re-invent the wheel. Take advantage of
  existing software and standards.

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• 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

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• 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.

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• B2B Process Outline
• 2. Vendor event database
• Event storagecontinued
• 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 IDS
  for a level 2 (content) errors.

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• 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.

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• 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

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• 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)

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• 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

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• 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

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• 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

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• 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

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• 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

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• 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

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• 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.

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• 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

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• 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.

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• 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.

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• 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

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• 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

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• 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.

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• B2B Process Outline
• Contact Information
• Jerry Edwards
• jkedwards2002_at_hotmail.com
• 650-799-6699