solyndra confidential northern california oaug solyndra makes transition to multi-org planning aaron...

Solyndra Confidential

Northern California OAUGSolyndra makes transition to multi-org planning

Aaron Baird, Business System Manager, Solyndra SCPManoj Rathi, Consulting Manager, US Jade

January 13, 2011


Introductions

Aaron BairdBusiness System Manager, Solyndra SCP

Manoj Rathi CSCPConsulting Manager, Jade GlobalOracle certified Advanced Planning Implementation ChampFeatured speaker on OAUG forums

2


Safe Harbor Statement

The following is intended for information purposes only, and may not be

incorporated into any contract. It is not a commitment to deliver any

services, material, code, or functionality, and should not be relied upon

in making purchasing decisions.

The development, release, and timing of any features or functionality

described for Oracle’s products remains at the sole discretion of Oracle.

The company information shared in this presentation may not be used

by anyone, except with a prior written permission.

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Agenda

•About Solyndra•Challenges with SCP and before Fab 2•New Fab Requirements•About Jade Global•Solution

–Supply Chain Planning–Inventory Planning–Production Planning–Warehouse Management–Inter-org transactions

•Challenges•Benefits•Q&A

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About Solyndra Inc.

Product• Solyndra designs and manufactures

proprietary cylindrical modules incorporating copper indium gallium diselenide (CIGS) thin-film technology.

• Panels employ cylindrical modules which capture sunlight across a 360-degree surface capable of converting direct, diffuse and reflected sunlight into electricity.

Manufacturing• 23 steps to manufacture; cleaning,

deposition, scribing, binning, insertion, filling , testing, panel framing and flash testing.

• Solyndra had produced over 16 million modules, approximately 370,000 modules each week.

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Supply Chain Planning (SCP) Challenges

• 24x7; operations always on.

• High volume inventory movement; inbound, warehousing, outbound.

• Numerous and complex sub inventories

– Raw, spares, FGI

– Onsite, offsite, 3PL, overseas

– accurate containment of restricted inventory

• Complex routings

– Inbound grading

– Movement to Production Kanbans

– Movement to Maintenance Stores and carts

• Complex Allocation rules

– Lot status; Raw and FGI material grading

– Packaging; comingled packaging sizes.

– Shelf life; time sensitive material.

– FIFO

– Customer specific; ensure correct grades and power.

– Serial number control.

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Solyndra SCP before Fab 2

• Solyndra had been using single org planning using ASCP and inventory planning processes.

–ASCP for supply forecasting.

– Inventory planning to forward move goods from Main Stores to Fab Stores and or Production Kanbans.

• WMS being used for pick rules, put away rules and lot status control.

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Single Inventory Organization

ORG A

Y

BLDG 1

Sales Order Execution

D>S

Shipping Execution

Min.Max Replenish

Fab 1 FGI

MRP

Shipping Execution

Procurement

ASCPBOS

ASCPPanel

forecast

Direct Inventory

Order Managemen

t


Fab 2 Multi Org Business Requirements

• Fab2 Supply and FGI.– Org B pulls all Raw material from Org A.

– Org B ships FGI to Org A.

• With the new fab, Solyndra had to upgrade to multi-org planning with introduction of inter-organization transfers.

– Plan for aggregated raw material procurement for both fabs.

– Inventory planning (pull) across orgs.

– Shipping and receiving documents for internal orders

– Separate set of rules for internal material movement.

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Org BOrg A

Y

N

BLDG 1

Sales Order Execution

D>S

Shipping Execution

Shipping Execution

Min.Max Replenish

Fab 1 FGI

MRP

Shipping Execution

Inter Company

Order

Purchase orders

Inter Company

Order

ASCPBOS

forecast

BLDG 2

ASCP Fab1Production

forecast

ASCP Fab2Production

forecast

Fab 2 FGI

Direct Inventory

Min.Max Replenish

Order Managemen

t

Org Inventory Planning

Fab2 Planned

Stock level

Fab1 Planned

Stock level

About Jade Global

© 2011 Jade Global, Inc. All rights reserved. www.jadeglobal.com 9Norcal OAUG Training Day, 04/18/23. Confidential.

Your Long Term IT Services Partner for Growth• Enterprise System Integrator• Served more than 50 customers for over 10 years

• Oracle Platinum Partner

• Oracle Certified Accelerate Solution Provider

• Strategic Partnerships

• Experience with Global Implementations

• Global Delivery Capability – US, India, China, Israel

• Right Shore Delivery Model

• Right Size

• SAS 70 Certified


Multi Org Solutions

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Oracle EBS Master Scheduling Production Planning FGI

Advanced Supply Chain Planning (ASCP)

Direct and Consumables

Inventory Planning Direct and Spares Production KanbanMaintenance stock room

Panel to FGI stores

Internal Req. / Internal Sales Order(IR/ISO)

Pick, Pack, Ship Pick, Pack, Ship

Warehouse Management System(WMS)

Lot controlLocation routing

Lot controlLocation routing


Master SchedulingAdvanced Supply Chain Planning (ASCP)

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Fab2 FORECAST

ITEMS

SOURCE RULE

ASSIGNMENT

SOURCE RULE

Fab 2 FORECAST

SET

Fab 1 FORECAST

SETPLAN

MRP; COLLECTION

& LAUNCH

PLANNER WORK BENCH

PURCHASE REQUISITION

FAB 1Org Item attribute

Org Min Max Planning

Import Requisitions

PLANNED STOCKING

LEVEL ITEMS

Fab 1 FORECAST

ITEMSBOM

BOM

PURCHASE ORDERS

Fab 1; Inventory Planning

Fab 1; Advanced Supply Chain Planning (ASCP)

Fab 2; Advanced Supply Chain Planning (ASCP)


Item Organization AttributesAttribute Name Controlled At FAB1 FAB2User Item Type Org Purchased item Purchased itemReservable Master Reservable ReservableBOM Item Type Master Standard StandardInventory Asset Value Org Yes YesInclude in Rollup Org Yes YesPurchased Master Yes YesPurchasable Master Yes YesReceipt Routing Org DirectInspection Required Org NOPlanner Org 99 99Make or Buy Org Buy BuyMRP Planning Method Master MRP and MPP planning MRP and MPP planningForecast Control Master Consume and Derive Forecast Consume and Derive ForecastEnd Assembly Pegging Master End Assembly/ Soft Pegging End Assembly/ Soft PeggingRound Order Quantities Master Round order quantities Round order quantitiesPreprocessing Lead Time Org 3 0Processing Lead Time Org 29 0Postprocessing Lead Time Org 1 0WIP Supply Type Master Push PushCustomer Ordered Master Yes YesCustomer Orders Enabled Master Yes YesInternal Ordered Master Yes YesInternal Orders Enabled Master Yes YesShippable Master Yes YesOE Transactable Master Yes YesPick Components Master No NoAssemble to Order Master No NoInvoiceable Item Master Yes YesInvoice Enabled Master Yes YesInventory Category Master Check ATP Org Material Only NoneATP Components Org None NoneATP Rule Org SOL ATP Rule

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Master Scheduling ASCP and Inventory Planning

Repetitive usageASCP and Sub inventory Planning

Target stocking levelOrg and Sub inventory Planning

Fab2 forecast

3PL STORES

BLDG 1 STOCK

Fab 1 forecast

MRP

PO receiptReceiving

subinventory

BLDG 2 STOCK

Move Order Internal Order

Min Max Planning

Min Max Planning

3PL STORES

BLDG 1 STOCK

PO receiptReceiving

subinventory

BLDG 2 STOCK

Move Order Internal Order

Min Max Planning

Min Max Planning

Org Level

Planning

Solyndra Confidential14

Production PlanningFab1 to Fab2 supply

FAB2 RAW

KANBAN 1

KANBAN 2

FAB2 KATO Inter-company Delivery

FAB2 SPARES CART

PUT RULE

PUT RULE

PICK RULE

PICK RULE

RCVLOC

RECEVING TRANSACTION

DEFAULT

WMS ALLOCATION

RULE

WMS DESTINATION

RULEMIN MAX

PLANNING

Counting

MRF Process

MRF Process

MIN MAX PLANNING

CCRF

WMS ALLOCATION

RULE

WMS DESTINATION

RULE

Fab2 PRODUCTION

MAINTENANCE

CONSIGNMENT

RAW

SPARES

MISC

PICK RULE

INTERNAL ORDER

SHIPPING

ORDER IMPORT

Inter Org Receipt

IMPORT REQUISITIONS

CREATE INTERNAL ORDERS

INTRANSIT

Fab1


WMS Business Rule

Pick rules

• Internal Order Pick Rule; Fab 1 to Fab 2

– Lot status

– Shelf life; not expired, sort by

– FIFO

– Sub inventories

– owning party; SOLYNDRA before Supplier

– RMA rules, no restrictions apply

• Replenishment Move Order Pick Rule

– Lot status

– Shelf life; not expired, sort by

– FIFO

– Owning party; SOLYNDRA before Supplier

– When Requisition Move order, no restrictions apply

• Internal Order Pick Rule; Fab 2 to Fab 1

– Lot status

– SN attribute; Born On date > 4 hrs, restricts entire delivery.

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Put Away Rules

•Move Order Transfer

– Item to destination.

– Source sub inventory to destination


Shelf life control; PO Receipt to Stock

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CONSIGNMENT

RAW

SPARES

MISC

PICK RULE

INTERNAL ORDER

SHIPPINGRECEIPT BLDG1.RAW

BLDG2.RAW

BLDG1.SPARES

BLDG2.SPARES

MIN MAX PLANNING

IMPORT REQUISITIONS

CREATE INTERNAL ORDERS

ORDER IMPORT

FAB 1; CO 2 FAB 2; CO 5

Shelf life control; Warehouse movement

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WMS Pick Rule; Lot Expiration date


Shelf life control; Production containment

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BLDG2.RAW EQUIP A EQUIP B EQUIP C EQUIP DACCT ISSUE

MRFPICK RULE

Min Max

PRODUCTION

FAB2

Telnet Task; REPL

WMS Pick Rule; Expiration date.


FGI Fab 2 to Fab 1

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CM to Oracle Interface

PRODFAB2 ENG STORES

FAB2 FGI STORES

N

Y

3PL ENG STORES

FAB1 FGI STORES

PICK RULE

PICK RULE

INTERNAL ORDER

INTERNAL ORDER

Ship Confirm Recieve

Ship Confirm

Recieve

Internal ReqFAB2

Internal ReqFAB1

Panel Conversion

ENG

FGI

FGI

ENGFab 2 (Co 5)

Fab 1 (Co 2)


Challenges

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Technical

• Item attributes; Org vs. Master

• Source rules; inter company

• Planner work bench

• Internal Requisitions; manual and planned

• Rick release, ship confirm, receive

• Shipping documents; SN and Lot number

• WMS rules; ship delay, Shelf life, lot status

Business

• Logistics, Planning, Purchasing process changes needed to effectively support Fab 2 and Fab 1.

• Business user participation critical to being successful CRP, UAT, Production support.


Benefits

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Continuing to leverage EBS benefits to support dynamic requirements

• Lot status control for material containment.

• WMS picking rules.

• WMS put away rules.

• IR/ISO for intra org movement.

• Shelf lift control; Lot expiration control.

• Multi Org planning; future Org expansion.

• Counting; WMS/Mobility


&AQ

Global Headquarters

1731 Technology Drive, Suite 350

San Jose, CA 95110

877-JADE-4IT (523-3448)

http://www.jadeglobal.com

Boston Area Office

1900 West Park Drive, Suite# 280

Westborough, MA 01581

(508) 983-1457

Jade Global - India

E-Space IT Park, A-3, 2nd Floor,

102 D/E, Wadgaon Sheri,

Pune-Nagar Road, Pune 411-014

Phone: 91-2066081500

VOIP: (408) 907-2730 (408) 834-8606

Norcal OAUG Training Day, 04/18/23. Confidential.© 2011 Jade Global, Inc. All rights reserved. www.jadeglobal.com

For More Information

23

Manoj RathiConsulting Manager

[email protected]

mailto:[email protected]

solyndra confidential northern california oaug solyndra makes transition to multi-org planning aaron...

Documents

solyndra confidential

solyndra challenges

solyndra confidential

single org planning

product solyndra designs

inventory planning processes

multiorg planning aaron

fab stores