bill of material (1).pdf
TRANSCRIPT
Oracle
Applications 11i
Bill of Materials
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Introduction
Overview of Bill of Material
Oracle Manufacturing and Oracle Order
Management use bills of material to store lists
of items that are associated with a parent item
and information about how each item is
related to its parent.
Oracle Manufacturing supports standard,
model, option class, and planning bills of
material.
Can create either an engineering or
manufacturing bill, copy an existing bill, or
reference a common bill.
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Bill of Material
BOM Item
Sub Assembly1 Phantom Sub
Assembly
Component1 Component2
Sub-
Component1
Sub-
Component …
Sub-
Component1
Sub-
Component …
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Product integration
Oracle Bills of Material integrates with the
following applications
Oracle Inventory
Oracle Engineering
Oracle Work in Process
Oracle Purchasing
Oracle Master Scheduling/MRP and Oracle
Supply
Chain Planning
Oracle Order Entry
Oracle Cost Management
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Bill of Material Types
Standard
Model
Option Class
Planning
Engineering
Phantom
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Bill of Material Types (Contd.)
Standard : A standard bill of material is the most
common type of bill and lists the mandatory
components, the required quantity of each
component, and information to control work in
process, material planning, and other Oracle
Manufacturing functions.
Model : A model bill of material defines the list of
options and option classes you can choose in
Oracle Order Management to order a
configuration.
Planning : A planning bill of material is a bill of
material structure that includes a percentage
distribution for its components. The percentages
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Navigation Bill of materials
Bill of materials
Bills
Bills
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Main page C
om
ponents
Various tabs available
Choose buttons to perform related tasks:
Substitutes :- Assign substitute components
Designators :- Create reference designators
Bill Details :- Reference common bills
Revision :- Define item revisions
BOM Item
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Components
Bills of Material restricts the types of items
you can assign as components based on the
type of bill you are defining.
Valid Parent/Component Relationships
Parent BOM Item
Type
Component BOM
Item Type
Standard Item Standard Item
Model Item Standard Item,
Model Item,
Option Class Item
Option Class Item Standard Item,
Model Item,
Option Class Item
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Revisions
Can define any number of revisions for
the item
Revisions are sorted according to
ASCII rules. Therefore, cannot use
revision 10 after revision 9 because,
according to ASCII sorting, 10 precedes
9.
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Revisions (Contd.)
List all the Revisions for BOM Item.
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Substitute Component
Substitute Component. E.g. A 40GB HDD can be
substituted by a 60 GB HDD
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Reference Designators
Reference designators are sequenced
comments and instructions that pertain to a
component.
The warning indicates that the reference
designators cannot exceed the component
quantity. If qty related check box is
unchecked then the designators can
exceed component quantity.
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Alternate Bills
Alternate field is used
to create alternate bills
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Copying Bill Information
You can save time defining new, similar
bills by copying their information rather
than creating them manually.
You can copy a bill from your current
organization or from another
organization that shares your same
item master organization.
You can then modify your new bill as
necessary.
You can copy any revision of a primary
or alternate bill.
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Copying Bill Information
(Contd.)
Tools Copy Bill
from. To copy from
existing bill
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Copying Bill Information
(Contd.)
Organization where
bill exists
Select Item whose bill is to
be copied
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Copying Bill Information
(Contd.)
The following message
is displayed when copy
button is pressed.
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Copying Bill Information
(Contd.)
The components, substitutes, designators etc are
copied for this bill.
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Common Bills of Material
If two or more organizations
manufacture the same item using the
same bill of material, you can define the
bill in one organization and reference it
from the other organizations.
You cannot reference another bill or
routing as a common if that bill or
routing also references a common. In
other words, you cannot create a chain
of common references.
You can only reference another bill or
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Common Bills of Material
(Contd.) Tools Create
common bills
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Common Bills of Material
(Contd.) Single Organization: Enter the organization and item names where the common bill
needs to be created.
Organization Hierarchy: Enter the required name of the organization hierarchy. In
this case, the processing is done for all organizations below the current
organization in the chosen organization hierarchy.
All Organizations: Then processing is done for all organizations that have the same
item master organization as the current organization.
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Common Bills of Material
(Contd.)
When clicked on OK a
request is submitted.
The status of common
BOM creation can be
seen from view log of
concurrent request.
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Practice
Create a BOM. Add components and other
necessary details for BOM. Create
Substitute components and Reference
Designators.
Create a new BOM by copying an existing
BOM
Create an alternate BOM for an item in an
organization.
Enable an item in a second organization
and copy a BOM from the first
organization.
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Routings
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Introduction
A routing defines the step–by–step
operations you perform to manufacture
a product.
Each routing can have any number of
operations.
For each operation specify a
department that determines the
resources you may use for that
operation.
Routings are used to specify the
processes that are used to manufacture
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Primary and Alternate Routings
A primary routing is the list of
operations most frequently performed
to build a product.
When you define a new primary
routing, you specify only the item (no
alternate name) and you can assign a
routing revision.
You can define one primary routing and
many alternate routings for an item.
You can define an alternate routing to
describe a different manufacturing
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Dynamic Routing
Paths that jobs take are not always
known at creation. Depending on initial
operations and their results, operation
flexibility is frequently required.
There can be numerous possibilities
defined as part of a routing network,
any one of them being selectable based
on the outcome of the last operation,
E.g. A Chemical product that undergoes
some chemical reaction.
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Creating a Routing
For each routing, define the operations,
the sequence to perform them, and the
resources required at each operation.
You can define either a primary or an
alternate routing
You must define at least one
department before you can create a
routing
BOM Allowed must be set to Yes for the
item you are creating a routing
You assign department resources to an
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Overview (Contd.)
Resources are anything— except
component material used to
manufacture, cost, or schedule
products.
A department is a collection of
resources designed to perform certain
tasks.
A department class is a collection of
departments.
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Overview (Contd.)
Department Class - Production
Department: Machining Department: Welding
Shift 1 Machinist
Drill
Press
Welding
Torch
Welder
Shift 2
Shift 1
Shift 2
Shift 1
Shift 1
Resources
Department
Department
Class
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Creating a Department Class
Department classes are used to group departments for shop floor scheduling
and control, and to identify manufacturing cells and flexible machine
centers. Department classes are used for reporting purposes.
Navigation
Setup
Department
Classes
Departments button
display the departments
assigned to this
department class and the
dates when these
departments can no
longer be assigned to
routing operations.
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Defining a Department
A department is an area within your
organization that consists of one or
more people, machines, or suppliers,
where you want to collect costs, apply
overhead, and compare load to
capacity.
You assign a department to each
operation in a routing, and assign
resources that are available for that
department.
Navigation
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Defining a Department (Contd.)
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Defining a Department (Contd.)
Click Resources button on the Departments page
Each resource can be
assigned to any
number of
departments;
multiple resources can
be assigned to each
department.
For owned resources, indicate
whether this department can
share
the resource and capacity with
other departments.
Enter the number of capacity units
(resource units) available for
this department, for example, the number
of machines for a
machine resource.
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Defining a Resource
Use resources to define the time an
assembly spends at an operation and
the cost you incur at the operation.
A resource is anything you require to
perform, schedule, or cost, including
but not limited to employees,
machines, outside processing services,
and physical space.
A resource and usage rate for all
scheduled activities is required in a
routing.
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Defining a Resource (Contd.)
Bills of Material Routings Define Resources
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Defining a Resource (Contd.)
Click on the Employees Button in Resources window
You can define the roles which represent what an employee can do
for a required task.
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Creating a Routing
Bills of material
Routings
Routings
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Creating a Routing (Contd.)
Item for which routing is to
be created
Organization
code
Populate for
alternate
routing
Department
name
Operation
sequence
number
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Assigning Operation Resources
Resource
name
Item: When charges fluctuate with
quantity change.
Lot : When resource usage quantity
is the amount required per job or
schedule
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Assigning Operation Resources
(Contd.)
Two or more resources can be scheduled to be
working concurrently within the same job operation
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Assigning Operation Resources
(Contd.)
Determine how each resource
is charged in Work in Process.
You can charge resources
manually or automatically
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Assigning Operation Resources
- Alternate
Optionally, you can define substitute resources for each primary
resource group defined. This enables you to specify resource
sequences that can replace the primary resource group
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Creating Routing Revision
The implementation date, which is either the date the revision
was added or the date the routing was transferred from Oracle
Engineering, is displayed. If the routing is transferred from
Engineering, the ECO text is displayed
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Routing Details
Completion Subinventory and Locator can be entered here.
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Creating Custom Deletion
Constraints
Use custom deletion constraints to enforce specific business rules.
Custom deletion constraints prevent the deletion of bills or routings if
your data meets the conditions set forth in the constraint.
Navigation
Bill of Materials
Setup
Delete Constraint
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Lead Time
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Lead Time Definitions
Fixed LeadTime
Fixed Leadtime is the portion of leadtime that
is independent of order quantity. This could
be setups, teardown, batch processes or
anything else that requires time to do a lot.
Fixed leadtimes for an item can be entered
manually.
A manually entered leadtime will be replaced
by the leadtimes generated by the
Manufacturing Leadtime rollup
Variable LeadTime
VARIABLE LEADTIME is the portion of
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Lead Time Definitions (Contd.)
PRE-PROCESSING LEADTIME
Pre-Processing Leadtime is the time required
to release a purchase order.
It is used for Purchase orders, discrete jobs
and repetitive lines.
It can include the requisition processing and
any approval cycles required.
It can also be used for the time necessary to
create internal paperwork for a discrete job or
repetitive line from the time you learn of the
requirement.
PROCESSING LEADTIME
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Lead Time Definitions (Contd.)
CUMULATIVE MANUFACTURING
LEADTIME
Cumulative Manufacturing Leadtime is the
time required to make an assembly if all raw
materials are in stock.
This assumes that you must manufacture
every assembly, level by level. BOM
automatically calculates this value.
CUMULATIVE TOTAL LEADTIME
CUMULATIVE TOTAL LEADTIME is the time
required to make an assembly if no raw
materials are in stock.
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LeadTime Definitions (Contd.)
Inventory
Item
Organization Item
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Cost Rollup
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This-Level and Previous-Level
Costing Oracle Cost Management (OCM) uses this-
level and previous-level costing concepts.
This-level costs are the routing costs of
the assembly.
Previous-level costs are the component
costs of the assembly, including the
routing costs of those components
Previous-level costs =
Component costs
This-level costs =
Routing costs
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This-Level and Previous-Level
Costing (Contd.)
This-Level Costs
The outside processing, resource, and
overhead costs at the current level of an
assembly
Any material overheads earned upon
completion of an assembly
Previous-Level Costs
The material, material overhead, outside
processing, resource, and overhead costs of
the components used in the manufacture of
an assembly
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Single-Level Versus Full Cost
Rollup Item: Bicycle Single-level rollup: 110.00 Full cost rollup: 120.00
Item: Frame assembly QPA: 1 Cost: 80.00 Full cost rollup: 90.00
Item: Wheel QPA: 2 Cost: 10.00 (old) Cost: 15.00 (new)
Item: Handlebar QPA: 1 Cost: 20.00 (old) Cost: 30.00 (new)
Item: Frame QPA: 1 Cost: 50.00
Item: Seat QPA: 1 Cost: 10.00
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Single-Level Versus Full Cost
Rollup (Contd.) Full Cost Rollup
A full cost rollup first performs a bill of material
explosion for the assemblies to determine the
structure to the lowest level. It then builds the
cost of the assemblies starting with the lowest
level and works up the structure to the top-
level assembly.
This method gives you the most current costs
for your assemblies because it reflects the
most current bill of material structure and
component costs for your assemblies.
You cannot rollup costs in the frozen or
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Single-Level Versus Full Cost
Rollup (Contd.) Single-Level Cost Rollup
Use a single-level rollup to avoid rolling up
costs at lower levels. A single-level rollup
looks only at the first level of the bill structure
of each assembly being rolled and then rolls
the cost for the items at this-level into the
parent.
This method does not reflect structure or cost
changes that have occurred at levels below
the first level of your assemblies.
Use single-level rollups to assign costs to new
assemblies when you do not want to roll up
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BOM and Routing Open Interface
- Bill of Materials
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Interface Tables
BOM_BILL_OF_MTLS_INTERFACE
BOM_INVENTORY_COMPS_INTERFAC
E
BOM_ASSY_COMMENTS_INTERFACE
BOM_REF_DESGS_INTERFACE
BOM_SUB_COMPS_INTERFACE
MTL_ITEM_REVISIONS_INTERFACE
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Interface Tables (Contd.)
In order to import a BOM with
components, you need to populate:
BOM_BILL_OF_MTLS_INTERFACE
BOM_INVENTORY_COMPS_INTERFACE
If you want to assign standard comments,
reference designators, and substitute
components to your BOM, you need to
populate:
BOM_ASSY_COMMENTS_INTERFACE
BOM_REF_DESGS_INTERFACE
BOM_SUB_COMPS_INTERFACE
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BOM_BILL_OF_MTLS_INTERF
ACE table REQUIRED COLUMNS FOR
BOM_BILL_OF_MTLS_INTERFACE.
ASSEMBLY_ITEM_ID
ORGANIZATION_ID
ASSEMBLY_TYPE
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BOM_BILL_OF_MTLS_INTERFAC
E table (Contd.)
REQUIRED COLUMNS FOR
BOM_BILL_OF_MTLS_INTERFACE
ASSEMBLY_ITEM_ID
ORGANIZATION_ID
ASSEMBLY_TYPE
PROCESS_FLAG
If you create an alternate BOM, you must
also enter a value in the
ALTERNATE_BOM_DESIGNATOR
column.
If the BOM you import references a
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BOM_INVENTORY_COMPS_INTE
RFACE table
REQUIRED COLUMNS FOR
BOM_INVENTORY_COMPS_INTERFAC
E TABLE
PROCESS_FLAG
COMPONENT_ITEM_ID
COMPONENT_SEQUENCE_ID
OPERATION_SEQ_NUM
EFFECTIVITY_DATE
BILL_SEQUENCE_ID
You must also specify a value in the
ALTERNATE_BOM_DESIGNATOR
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BOM_ASSY_COMMENTS_INTER
FACE table
REQUIRED COLUMNS FOR THE
BOM_ASSY_COMMENTS_INTERFACE
TABLE.
STANDARD_REMARKS_DESIGNATOR
BILL_SEQUENCE_ID
PROCESS_FLAG
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BOM_REF_DESGS_INTERFA
CE table REQUIRED COLUMNS FOR
BOM_REF_DESGS_INTERFACE TABLE.
COMPONENT_REFERENCE_DESIGNATOR
COMPONENT_SEQUENCE_ID
PROCESS_FLAG
You can only import data into the
BOM_REF_DESGS_INTERFACE table
for standard components assigned to
standard, model and option class BOMs.
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BOM_SUBS_COMPS_INTERF
ACE table REQUIRED COLUMNS FOR
BOM_SUBS_COMPS_INTERFACE
TABLE.
SUBSTITUTE_COMPONENT_ID
SUBSTITUTE_ITEM_QUANTITY
COMPONENT_SEQUENCE_ID
PROCESS_FLAG
You can only import data into the
BOM_SUBS_COMPS_INTERFACE table
for standard components assigned to
standard, model and option class BOMs.
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Import Rules
Different values of PROCESS_FLAG are
All inserted rows must have the PROCESS_FLAG set to 1 (Pending)
Import program validates records with PROCESS_FLAG 1. If the assign or validate procedure fails for a row, the program sets the PROCESS_FLAG to 3 (Assign/Validation Failed)
If a row fails on import, the program assigns a value of 4 (Import Failed) to the PROCESS_FLAG
Successfully imported rows have a PROCESS_FLAG value of 7 (Import
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Tracking error record
To identify the error message for a failed
row, the program automatically populates
MTL_INTERFACE_ERRORS table with
the same value as the TRANSACTION_ID
value.
Each error has a value for the
MESSAGE_NAME and REQUEST_ID
columns in the error interface table.
MESSAGE_NAME column corresponds to
messages stored in the Oracle Application
Message Dictionary.
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Interface Tables for Routings
BOM_OP_ROUTINGS_INTERFACE
BOM_OP_SEQUENCES_INTERFACE
BOM_OP_RESOURCES_INTERFACE
BOM_OP_INSTRUCTIONS_INTERFACE
MTL_RTG_ITEM_INTERFACE
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Interface Tables (Contd.)
To import a routing with operations and
resources, you need to populate the
following tables:
BOM_OP_ROUTINGS_INTERFACE
BOM_OP_SEQUENCES_INTERFACE
BOM_OP_RESOURCES_INTERFACE
If you want to assign standard instructions
to your routings, then you populate the
BOM_OP_INSTRUCTIONS_INTERFACE
table
If you enter a value in the
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BOM_OP_ROUTINGS_INTERF
ACE table REQUIRED COLUMNS FOR THE
BOM_OP_ROUTINGS_INTERFACE
TABLE.
PROCESS_FLAG
ASSEMBLY_ITEM_ID
ORGANIZATION_ID
ROUTING_TYPE
If you are creating an alternate routing,
you must also enter a value in the
ALTERNATE_ROUTING_DESIGNATOR
column.
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BOM_OP_SEQUENCES_INTE
RFACE table REQUIRED COLUMNS FOR THE
BOM_OP_SEQUENCES_INTERFACE
TABLE
PROCESS_FLAG
ROUTING_SEQUENCE_ID
OPERATION_SEQ_NUM
DEPARTMENT_ID
EFFECTIVITY_DATE
You must also specify a value in the
ALTERNATE_ROUTING_DESIGNATOR
column if you assign an operation to an
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BOM_OP_RESOURCES_INTE
RFACE table REQUIRED COLUMNS FOR THE
BOM_OP_RESOURCES_INTERFACE
TABLE.
PROCESS_FLAG
RESOURCE_SEQ_NUM
RESOURCE_ID
OPERATION_SEQUENCE_ID
You must specify a value in the
ALTERNATE_ROUTING_DESIGNATOR
column if you assign resources to an
alternate routing and have not entered a
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BOM_OP_INSTRUCTIONS_INTE
RFACE table
REQUIRED COLUMNS FOR THE
BOM_OP_INSTRUCTIONS_INTERFACE
TABLE.
OPERATION_SEQUENCE_ID
OPERATION_DESCRIPTION_CODE
PROCESS_FLAG
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MTL_RTG_ITEM_REVS_INTE
RFACE table REQUIRED COLUMNS FOR THE
MTL_RTG_ITEM_REVS_INTERFACE
TABLE.
PROCESS_REVISION
ORGANIZATION_ID
INVENTORY_ITEM_ID
PROCESS_FLAG
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Import Rules
Different values of PROCESS_FLAG are
All inserted rows must have the
PROCESS_FLAG set to 1 (Pending)
Import program validates records with
PROCESS_FLAG 1. If the assign or validate
procedure fails for a row, the program sets the
PROCESS_FLAG to 3 (Assign/Validation
Failed)
If a row fails on import, the program assigns a
value of 4 (Import Failed) to the
PROCESS_FLAG
Successfully imported rows have a
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Tracking error record
To identify the error message for a failed
row, the program automatically populates
MTL_INTERFACE_ERRORS table with
the same value as the TRANSACTION_ID
value.
Each error has a value for the
MESSAGE_NAME and REQUEST_ID
columns in the error interface table.
MESSAGE_NAME column corresponds to
messages stored in the Oracle Application
Message Dictionary.
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