MES PRISM- ERP LOT NUMBER CONVERSIONS

MES Program

Lot Number Length Limitation in PAS-X

Lot# length <= 10 CHARACTERS >10 CHARACTERS

Impact • All Raw Material Onhand Lots in
Shanbally

• All Raw Material Onhand Lots in Novato

if inventory from Novato will be
transferred over to Shanbally
Assumption No Existing DS / Intermediate / Kit /
Buffer Media inventory lots to be
migrated to PAS-X
 MES Program
Options
#1 #2 #3

Lot Transformation using Inventory Adjustment Lot Transformation using OPM Batch Txn Transfer Only Numeric Value to MES

Issue out the existing inventory and Receive in with new Consume existing inventory and Yield the inventory with Transfer Only Numeric value of the existing inventory lot
lot number and traceability to the existing lot number in the new lot number against OPM Batches. number to MES
ref field.

System Configuration/Modifications: System Configuration/Modifications: System Configuration/Modifications:

Label format to be configured for Inventory Adjustment NA Interface logic to be updated (3 weeks effort)
Transaction.
Genealogy/Traceability reports to be updated Data Migration: Data Migration:
350+ New one time use recipes NA
Data Migration: 1000+ OPM Batches
5000+ Transactions 5000+ Transactions Warehouse: NA
1000+ Lot attribute updates 1000+ Lot attribute updates
Costing: NA
Warehouse: Relabel all existing inventory with new lot Warehouse: Relabel all existing inventory with new lot
number number Cons:
Lot Number in Oracle and MES systems will be different.
Costing: Manual cost adjustment may be needed. Costing: NA
Open Items:
Cons: Cons: Lead any misalignment during transactions?
Traceability between the new lot# and existing lot# will be High volume of master day and transactions The same numeric number will be displayed across
broken in Oracle. multiple item numbers in MES
Open Items: The lot number displayed in the reports on PAS-X (only
Open Items: How LIMS will handle the new lot number? numeric) and Oracle (item number with numeric) systems
How LIMS will handle the new lot number? Any QC release documents referring to existing lot would be different.
Any QC release documents referring to existing lot number to be updated?
number to be updated?

Option# 1 – Lot Transformation using Inventory Adjustment
Requirements
Update Genealogy & Traceability
Reports
Configure Label format for Inv.
Adjustment Transactions
Update Lot Prefix Item attribute for
raw material items
ACCOUNT
Perform Inventory Adjustment
ISSUE Transactions (using Tool)
Update Lot attributes (Origination &
Expiry date, lot status)
Perform cost adjustment
Apply Labels to all existing
inventory
ACCOUNT NEW LOT NUMBER with 10 Chars Max
RECEIPT *Reference with Old Lot Number for Traceability
Discuss steps to reconcile New/Old
lot number transfers to LIMS.
MES Program
Reason
To refer the existing/supplier lot number from
the cross ref value
To print raw material labels for new lot
numbers
To generate lot numbers with new lot
numbering scheme
For transforming the existing lot number to
new lot number with 10 chars max.
To match the lot attributes of existing lot
numbers to the new lot numbers.
Apply manual cost adjustment for raw
material items that are received thru’
inventory adjustment txns.
To replace the existing label with new labels
with new lot numbers in MES format.
Oracle transfers lot numbers to LIMS every
time it gets created in EBS.
 MES Program

Pros
In Oracle EBS, Lot Number are transformed to match
the MES character length limitation
Cons
Genealogy will be broken in the system forms
Multiple Technology Changes required
Oracle Genealogy/Traceability report modification
New Label format configuration
LIMS transfer challenges (New & Old lot numbers)
Warehouse Resource needed to reapply labels for raw
material inventory.
Costing Resource needed to evaluate and adjust cost
for raw material items.
Volume of Transactions*
2500+ Account issue txns
2500+ Account receipt txns
1000+ Lot updates
*Inventory to be reduced as much as possible to limit the volume of
transactions

Option# 2 – Lot Transformation using OPM Batch (Work Order) Transactions
Requirements
Update Genealogy & Traceability
Reports
Configure Label format for Inv.
Adjustment Transactions Existing
Label format to be updated
Update Lot Prefix Item attribute for
raw material items
WIP ISSUE
Perform OPM Batch Transactions
(using Tool)
Update Lot attributes (Origination &
Expiry date, lot status)
Perform cost adjustment
Apply Labels to all existing
WIP inventory
Completion NEW LOT NUMBER with 10 Chars Max
Discuss steps to reconcile New/Old
lot number transfers to LIMS.
MES Program
Reason
To refer the existing/supplier lot number from
the cross ref value
To print raw material labels for new lot
numbers
To generate lot numbers with new lot
numbering scheme
For transforming the existing lot number to
new lot number with 10 chars max.
To match the lot attributes of existing lot
numbers to the new lot numbers.
Apply manual cost adjustment for raw
material items that are received thru’
inventory adjustment txns.
To replace the existing label with new labels
with new lot numbers in MES format.
Oracle transfers lot numbers to LIMS every
time it gets created in EBS.

Pros
In Oracle EBS, Lot Number are transformed to match the
MES character length limitation
System keeps the genealogy intact.
MES Program
Cons
Genealogy will be broken in the system forms
Multiple Technology Changes required
Oracle Genealogy/Traceability report modification
New Label format configuration
LIMS transfer challenges (New & Old lot numbers)
Warehouse Resource needed to reapply labels for raw
material inventory.
Costing Resource needed to evaluate and adjust cost for
raw material items.
Volume of Transactions (High)*
350+ Recipes (1 per RM item, one time use)
1000+ OPM Batches (1 per lot number)
2500+ WIP Issue Txns (for all locators)
2500+ WIP Completion Txns (for all locators)
1000+ Lot updates
*Inventory to be reduced as much as possible to limit the volume of
transactions

Option# 3 – Transfer ONLY numeric lot number value to MES
Transfer ONLY the NUMERIC
string of the lot number to MES
Requirements
EBS and MES interfaces (8 out of 20) to be
updated
Analyze and confirm all exiting raw
material lot numbers follow the same lot
numbering pattern.
MES Program
Reason
Logic to included to send only the numeric string in
the outbound interface and concatenate the item
number with the numeric string for the inbound
interface
To avoid any surprises during production
migration/transaction.

Pros
No changes to the existing lot records in Oracle EBS
No application of labels required for existing raw material
inventory
No cutover transactions required
MES Program
Cons
MES will have only the numeric string and will be sharing
the same numeric value across multiple raw material items.
Oracle EBS and MES interfaces to be updated to fulfill this
requirement*
*Resource and timeline impact to be assessed
 MES Program

Option #1: Miscellaneous Transactions

 Perform Miscellaneous Issue transaction for all existing Raw Material lots

 Then perform Miscellaneous Receipt transaction with new lot number

 For all new lots created, the old lot numbers are captured as a reference
in a DFF attribute

 For all new lots created, the supplier lot, Lot status and expiration dates
are updated as per old lot attributes
 MES Program

Option #1: Pros and Cons of Miscellaneous Transactions

Cons:

 Lot Genealogy report has to be modified to include the logic to consider these transactions.

 For the New lot numbers created by miscellaneous receipt duplicate samples will be created in
LIMS thereby duplicate samples for same lot.

 Custom program to be developed to print labels created by Miscellaneous receipts

 New label has to be applied manually for all existing Raw material inventory.

 Costing impacts - Actual cost adjustments / updates to be made

Pros:
 No impact to existing Master data.
 MES Program

Option # 2: Batch Transactions

 Create a Recipe for all Raw Material items for which on hand exists.

 Create a batch for each Raw material Item lot. Ex Create a batch for
Z1004. Ingredient lot consumed would be Z1004-18101 and the product
lot yielded would be 10001 etc. Similarly another batch for same item for
each of the different lots.

 For all new lots created, the supplier lot, Lot status and expiration dates
are updated as per old lot attributes
 MES Program

Option #1: Pros and Cons of Batch Transactions

Cons:

 Master data impact - New recipes have to be created @ 300 recipes

 High volume of Batch transactions- Batch has to be created for each raw
material lots which leads to @ 1000 to 1500 batch transactions
 New label has to be applied manually for all existing Raw material
inventory.
 Test document impact- Project team to discuss with QA / QC.

Pros:
 No impacts for Lot Genealogy Report
 No Costing impacts
 MES Program

Option # 3: Reduce / Stock out existing Raw material

On hand inventory

 Reduce Raw material inventory to Nil or minimum quantity

 Create new inventory by PO receipt with new lot numbers.

 Labels generated upon a PO receipt.

 MES Program

Option #3 : Pros and Cons Inventory reduction

Cons:

 Financial impact –Value of scrapping the existing raw material lots.

 Risk of delayed supply from suppliers.
 QA/ QC – Risk of delays in raw material lot release.
 Test document impact- Project team to discuss with QA / QC.

Pros:
 No impacts for Lot Genealogy Report
 No need to reapply labels.
 No impacts to Master Data.
 No impact to label generation
 No need to perform any new transactions.
 MES Program

Option # 4: Technical design change for all interfaces

 Change the existing interface design so that ERP sends only the numeric part of
the lot number. Ex if the lot number is Z2014-19101, the batch master interface
would only send 19101.

 All existing interface would have to be modified to send only the numeric part of
lot number as MES stores both item and lot number in concatenated format.
 MES Program

Option # 4 : Pros and Cons Technical design change.

Cons:

 Risk impact–Existing coding and design has to be changed and might

delay the testing phase.
 Risk of lot number duplication in MES
 Might impact project cost as technical resource has to be planned.
 Test document impact- Project team to discuss with QA / QC.
 Lot genealogy report has to be modified?

Pros:
 No need to reapply labels.
 No impacts to Master Data.
 No impact to label generation
 No need to perform any new transactions.