Post on 28-Mar-2018
A Day in the Life of a Planner
Copyright © 2009 Idhasoft Inc.. All Rights Reserved.Copyright © 2009 Idhasoft Inc. All Rights Reserved.www.idhasoft.com
Vision Packaged . Delivered
Build a seamless system for Fabless
semiconductor companies using OraclePresenter: Sid Nandi
&
Raul Tomasi
Sr. Manager IT
EXAR Corporation
NorCal OAUG Training Day
January 19, 2010
A Day in the Life of a Planner
Copyright © 2009 Idhasoft Inc.. All Rights Reserved.
• Idhasoft Introduction
• Key Challenges to the Semiconductor Industry
• Our Solution Approach
• Business and Application Solutions Modeling
• Lot Processing
• Yield based Costing
• Invoice Payments
• Tracking Distributor Inventory, Claim Processing and Revenue Recognition
• Supply chain Planning and Customer Commit (ATP)
• Pick and Ship (WMS)
• EXAR Implementation
• Implementation Key Success Factors
• Discussion and Q&A
Structure of the Presentation
A Day in the Life of a Planner
Copyright © 2009 Idhasoft Inc.. All Rights Reserved. 3
Global Operations
• $180 M Services Company
• 1200+ Employees
• 200+ Oracle Consultants
IndiaAtlantaLos Angeles
BostonNew York
Toronto
New JerseySan Francisco
Chennai
Hyderabad
Delhi
BangaloreMumbai
ERP Solutions Supply Chain Solutions Technology Solutions Staffing
Locations
Switzerland
Japan
Korea
Taiwan
Singapore
A Day in the Life of a Planner
Copyright © 2009 Idhasoft Inc.. All Rights Reserved.
xOracle Business Unit
Oracle
Licensing
Oracle
ebusiness
Suite
Oracle Fusion
Middleware
Managed
Support
Business
Intelligence
o Licensing Service
o ERP Implementation
o SOA & Middleware Technologies
o BI (OBIEE and Hyperion)
o Professional Services
o Infrastructure & 24/7 DBA Services
o Managed Services & India Development Center
Largest practice at Idhasoft - $60M in annual revenues
One Stop Shop
A Day in the Life of a Planner
Copyright © 2009 Idhasoft Inc.. All Rights Reserved.
Sample Customers
5
Vertical focus
Big Box RetailersBig Box Retailers
Department Stores Department Stores
OthersOthers
SemcnductorsSemcnductors
High TechHigh Tech
Internet
& Software
Internet
& Software
A Day in the Life of a Planner
Copyright © 2009 Idhasoft Inc.. All Rights Reserved.
Semiconductor Manufacturer
Distributor
OEM
OEM Hubs
Business Direct
Channel
Consumer Direct
3PL’s
Component Manufacturer
Contract Manufacturer
Evolving Challenges
• Complexity of Business
� Globalization
� Outsourcing
� Shorter Lifecycle
• Variability of Supply and Demand
� Less Customer Loyalty
� Mass Customization
� Shorter Order Lead Time
• Growth and Competition
� Mergers and Acquisitions
� Maximize Profitability During Growth
Evolving Challenges
• Complexity of Business
� Globalization
� Outsourcing
� Shorter Lifecycle
• Variability of Supply and Demand
� Less Customer Loyalty
� Mass Customization
� Shorter Order Lead Time
• Growth and Competition
� Mergers and Acquisitions
� Maximize Profitability During Growth
Global High Tech Business Flow
Business is ComplexPlanning happens in day’s, Execution happens in hours
A Day in the Life of a Planner
Copyright © 2009 Idhasoft Inc.. All Rights Reserved.
Design Complexity• Part Standardization
• Increasing Product Mix
• Engineering Changes to improve product
• Design cycle time, and development of customer-specific products
• Part/Designs standardization
Design Complexity• Part Standardization
• Increasing Product Mix
• Engineering Changes to improve product
• Design cycle time, and development of customer-specific products
• Part/Designs standardization
Supply Management• High component lead times
• Single Vs Multi Sourcing
• Leveraging global manufacturing and supply base
• Manage high volume Supplier Transactions
Supply Management• High component lead times
• Single Vs Multi Sourcing
• Leveraging global manufacturing and supply base
• Manage high volume Supplier Transactions
Demand Management• Customer Order changes several
times
• Inconsistent Forecast
• Demand fluctuations
Demand Management• Customer Order changes several
times
• Inconsistent Forecast
• Demand fluctuations
Planning & Configuration Management
• Managing the flow of materials & information through multiple stages of manufacturing, transportation & distribution
• Inventory Optimization
Planning & Configuration Management
• Managing the flow of materials & information through multiple stages of manufacturing, transportation & distribution
• Inventory Optimization
A Seamless Integrated System
High Tech Industry Challenges
A Day in the Life of a Planner
Copyright © 2009 Idhasoft Inc.. All Rights Reserved.
• Fabless Semiconductor - $200 Billion Industry and growing
• High Cost of Fabs move the industry towards Fabless
• Growth can happen in rapid manner
• Many Challenges
• Complex Manufacturing; High Lead Time
• High Volume and Mix
• Quick Response Time Needed
• Low Margin (in many cases)
• High Competition
• Low Product Life Cycle (Technology overrun)
• Fluctuating Demand
• High Inventory
• Poor Supply Chain Visibility
• Ability to Plan and meet customer Demand
• No Integrated Manufacturing System
Semiconductor Challenges
A Day in the Life of a Planner
Copyright © 2009 Idhasoft Inc.. All Rights Reserved.
• I wish I could build my business in order to:
o Configure (and reconfigure) processes rapidly to respond to change
and new business models,
o Support the reconfigured processes with technology –quickly,
o Identify shared functionality across divisions and geographies with
greater precision and granularity,
o Interface with customers and suppliers with greater ease, granularity
and precision, and have a far more sophisticated discussion about
«make or buy» than currently possible,
o Assess acquisition candidates based on a granular, effective and
realistic perspective of synergy and breakup values.
CEO’s Dream
A Day in the Life of a Planner
Copyright © 2009 Idhasoft Inc.. All Rights Reserved.
Simple & Flexible
A Day in the Life of a Planner
Copyright © 2009 Idhasoft Inc.. All Rights Reserved.
• Build a seamless Application System
• Understand the business
• Use standard Application System like Oracle
• Know your application system
• Plan your Master Data Management carefully
• Integrate using the right technology
• Do not forget report strategy
• Use Business Intelligence to gain competitive advantage
Our Solution Approach
Goal – Integrated Manufacturing System
3PL
A Day in the Life of a Planner
Copyright © 2009 Idhasoft Inc.. All Rights Reserved.
Business Process & Applications Modeling
• Common Source of Master Data ( Customers, Suppliers, Parts)
• Part Number and Attributes
• Product Structure
• Lot Number scheme & Lot Attributes
• Organization Structure
• Routing, Resources
• Cost Structures and how to manage it
• Purchasing Approval Hierarchy
• Invoice Matching process
• Reschedule and reservation process
• Pick and Ship Process
• Credit Check and Approval Process
• POS and Revenue Recognition Process
• RMA Process
• Service integration
• Month End Closing Process
obpm_whitepaper.pdf
A Day in the Life of a Planner
Copyright © 2009 Idhasoft Inc.. All Rights Reserved.
• Transactions related to Lot Based Jobs
– New Lot Based Job
– Lot Creation
– Move
– Scrap
– Update Job Quantity
– Job Split
– Job Merge
– WIP Lot Rename
– Lot Hold & Release
– Bonus
• Transactions related to Inventory Lots
– Lot Split
– Lot Merge
– Lot Transfer
– Lot Translate
– Lot Issue
– Lot Receipt
OSFM – Supported Transactions
A Day in the Life of a Planner
Copyright © 2009 Idhasoft Inc.. All Rights Reserved.
Lot Processing – Using Oracle OSFM
• Transaction Intensive
• User Interface
• Loose Couple Between WIP & Purchasing
Shortcomings
Solutions
• Workbench
• B2B Solution – Virtual Manufacturing System (VMS)
A Day in the Life of a Planner
Copyright © 2009 Idhasoft Inc.. All Rights Reserved.
Lot Processing Workbench
A Day in the Life of a Planner
Copyright © 2009 Idhasoft Inc.. All Rights Reserved.
Lot Processing Workbench
A Day in the Life of a Planner
Copyright © 2009 Idhasoft Inc.. All Rights Reserved.
Lot Processing Workbench
A Day in the Life of a Planner
Copyright © 2009 Idhasoft Inc.. All Rights Reserved.
• Features
– Automates collection & integration of supplier data
– Monitors data for problems & generates alerts
Lot Processing Automation
A Day in the Life of a Planner
Copyright © 2009 Idhasoft Inc.. All Rights Reserved.
Supplier Data Differs
A Day in the Life of a Planner
Copyright © 2009 Idhasoft Inc.. All Rights Reserved.
Supplier Integration - VMS
A Day in the Life of a Planner
Copyright © 2009 Idhasoft Inc.. All Rights Reserved.
Supplier Integration - VMS
A Day in the Life of a Planner
Copyright © 2009 Idhasoft Inc.. All Rights Reserved.
• Delivers instant access to critical info.
– Manufacturing views: orders, WIP, delivery schedule
– Exceptions: parts on hold
• Provides “early warning” system
– Automatically generates & sends email alerts
– Analyzes real-time data to identify potential problems
• Streamlines manufacturing operations
– Detects/cleanses imperfect data: lot splits, merges,
scrap, out of step movements
– Automates WIP/yield data from suppliers into Tier 1
ERP/yield systems
– Developed using scalable SOA and J2EE architecture
Powered by eSilicon Access and IdhasoftVMS – Key features
A Day in the Life of a Planner
Copyright © 2009 Idhasoft Inc.. All Rights Reserved.
VMS Flows
• WIP Processing
– WIP Updates - FAB Schedule to Finished Goods
– Correction Rules
– Resubmissions
– Lot Monitoring Alerts
– Setup Validation Alerts
• Browsing Capabilities
– Lots, Items, Routings, Channel, Transaction Processing,
Process Flow etc.
• Admin Pages Overview
– Control Panel
– Supplier Sources/Exception Summary
• Adding a New Supplier
• Internal Discoverer Reports
– Lot Report, Cycle Time, Yield Reports, Costed WO & Inventory
etc.
VMS – Key features
A Day in the Life of a Planner
Copyright © 2009 Idhasoft Inc.. All Rights Reserved.
Suppliers Data Supported
• FAB– TSMC(TSV), UMC(csv), SMIC(csv)
• Assembly and Test– Amkor (text), SPIL(XML), ISE(excel)
– ASE Singapore (XML),
– ASE Malaysia (XML)
– Unsem, Carsem
• Update Types– Status snapshots
– Transactional (Rosettanet 7B1)
– Transaction history
– Supplier specific proprietary transactions
• Adding a new Supplier support for automation is
easily doable
– Need Isolated data conversion specific to supplier
– Process Flow configuration
VMS – Supplier data Supported
A Day in the Life of a Planner
Copyright © 2009 Idhasoft Inc.. All Rights Reserved.
Important Reports
• Master Data Reports– Indented Bills of materials with Cost
– Item details Report
• Valuation Reports– Inventory Value
– WIP Value
• Variance Reports
– PPV Report
– IPV Report
– Yield Variance Report
• Transaction Reports– Lot Tracking Report
– Shipment Report
– BBB Report
– Horizontal Plan Report
A Day in the Life of a Planner
Copyright © 2009 Idhasoft Inc.. All Rights Reserved.
Item Number Subinventory Locator Lot Number Category Prod Code Quantity Cost Total Value Prod Family Item Class
S0880C0AG DB-AMKOR K1 DP2178.00 PHY.LXT9880 60350 3548 1.00 3548.00 PHY LXT9880
S0880C0AG DB-AMKOR K1 DP2177.00 PHY.LXT9880 60350 9107 1.00 9107.00 PHY LXT9880
S0880C0AG DB-AMKOR K1 DN9735.00 PHY.LXT9880 60350 8663 1.00 8663.00 PHY LXT9880
S0880C0AG DB-AMKOR K1 0652A05A PHY.LXT9880 60350 9135 1.00 9135.00 PHY LXT9880
S0880C0AG DB-AMKOR K1 0638A00A PHY.LXT9880 60350 3548 1.00 3548.00 PHY LXT9880
S0386E0BC DB-AMKOR K1 DR8751.00.1 T1/E1.LXT386 61275 30883 1.00 30883.00 T1/E1 LXT386
S0386E0BC DB-AMKOR K1 DR5172.00 T1/E1.LXT386 61275 30423 1.00 30423.00 T1/E1 LXT386
S0384E0BB DB-AMKOR K1 DR8750.00 T1/E1.LXT384 61250 16953 1.00 16953.00 T1/E1 LXT384
S0384E0BB DB-AMKOR K1 DR8749.00 T1/E1.LXT384 61250 16664 1.00 16664.00 T1/E1 LXT384
S0384E0BB DB-AMKOR K1 DR3988.00.1 T1/E1.LXT384 61250 2042 1.00 2042.00 T1/E1 LXT384
S0384E0BB DB-AMKOR K1 DP9949 T1/E1.LXT384 61250 7211 1.00 7211.00 T1/E1 LXT384
S0380E0BE DB-AMKOR K1 0541A13A T1/E1.LXT380 61225 4074 1.00 4074.00 T1/E1 LXT380
S0360E0AC DB-AMKOR K1 Z55007 T1/E1.LXT360 61200 5768 1.00 5768.00 T1/E1 LXT360
S0386E0BC DB-AMKOR K3 DR3987.00 T1/E1.LXT386 61275 12901 1.00 12901.00 T1/E1 LXT386
S0880C0AG DB-AMKOR K3 DP2178.00 PHY.LXT9880 60350 4278 1.00 4278.00 PHY LXT9880
S0880C0AG DB-AMKOR K3 DP2179.00 PHY.LXT9880 60350 8690 1.00 8690.00 PHY LXT9880
MONZA-SW DB-AMKOR K4 G67111.1 ETHERNET.CS3400 50125 2 1.00 1.78 ETHERNET CS3400
27-0024-00F DB-AMKOR K4 ETHERNET.CS3470 50150 628 1.00 628.00 ETHERNET CS3470
VALENCIA-A1-S DB-AMKOR K4 G67004.1 ETHERNET.CS3470 50150 434 1.00 434.00 ETHERNET CS3470
VALENCIA-A1-S DB-AMKOR K4 GY5991.1 ETHERNET.CS3470 50150 1208 1.00 1208.00 ETHERNET CS3470
KATANA-B3-S DB-AMKOR K4 FS5895.1 FRAMER.CS5000 51200 75 1.00 75.00 FRAMER CS5000
Sample Report – Inventory Value
A Day in the Life of a Planner
Copyright © 2009 Idhasoft Inc.. All Rights Reserved.
Horizontal Forecast Report for Supplier
A Day in the Life of a Planner
Copyright © 2009 Idhasoft Inc.. All Rights Reserved.
• Phase – I
Goal : Replace existing MES (FW) with OSFM and streamline Lot Processing
with scalable software and hardware infrastructure
• Build New Industry Standard Scalable Infrastructure
• Implement Oracle OSFM
• B2B Implementation – Supplier Integration
• AP Invoice Automation
• Go Live – Feb 21 ( 7 Months)
• Phase – II
• Stabilization, Reporting & BI etc…
EXAR Implementation
A Day in the Life of a Planner
Copyright © 2009 Idhasoft Inc.. All Rights Reserved.
EXAR ImplementationxEXAR Implementation
• Project preparation
o Project Team
o Project Plan
• Understanding the business Requirements
• Solution Modeling and Core Team Agreement
• Documentation and close Tracking of Issues
• Commitment to make the project a top priority
• Data Review & Cleansing
• Testing, Testing & Testing and Sign-Off
• EXAR Executive Management Involvement
Methodology
Challenges Faced
• Data Cleansing
• Supplier Data Quality
A Day in the Life of a Planner
Copyright © 2009 Idhasoft Inc.. All Rights Reserved.
Cultural Change – A Paradigm Shift
Planner/ Buyer
What can I do for you?
A Day in the Life of a Planner
Copyright © 2009 Idhasoft Inc.. All Rights Reserved.
Thank YouSid.nandi@idhasoft.com
650-517-9729
Discussion and Q&A