OPM Process Execution and OPM Standard Costing for Poultry Business

Question

I have a business requirement from the client at their Poultry Processing plant where the client feels that the OPM Execution steps are too cumbersome until closing the batches. The client wants to maintain minimum number of batches in Production: one for Primary, one for Secondary and one for Further Processing, rather than having multiple batches based on different formulas. There are 3 main types of processing which can be briefly described as follows:
A.) Primary Processing:
Live Birds (Ingredient) become Whole Dressed Chicken with Neck, without Neck, Liver, Heart, etc... (40 Finished Products)
e.g. Live Birds (Broiler) -> Whole Dressed Chicken with/without neck, Whole Dressed Chicken with/without neck, etc.
B.) Secondary Processing:
Only one type of Whole Dressed Chicken (from Primary Processing) become Chicken Cuts (80 Finished Products).
e.g.[Scenario B1] Whole Dressed Chicken (Broiler) -> Drumsticks, Thighs, Wings, Breasts, Backbone, etc.
[Scenario B2] Breasts -> Filets and Deboned Breasts (2 FGs)
[Scenario B3] Thighs -> Thighs in Plain Bag
Please note that the Whole Dressed Chicken is also sold as a Finished Good as well as an Ingredient for the Secondary Processing.
C.) Further Processing:
Chicken Cuts become 40 Finished Products
e.g Filets -> Chicken Nuggets, Chicken Fries, etc...
The client is using Standard Costing method for its OPM Financials and all the finished products (160 Products in all) are having different production cost. Please note that 1 kg of Chicken Wings is not equal to 1 Kg of Chicken Thighs. Different body parts have different costs. In order to alleviate the maintenance of multiple batches per day on the production floor, the client wishes to have minimum batches. We therefore would wish if you can confirm the below approach to be correct?
a.) OPM Process Execution:
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EITHER should I (Option 1):
a.) Create ONLY 3 Formulas for Primary, Secondary and Further Processing . The 3 Formulas will have all the processing line Finished Products grouped together (as per the scenarios explained above). Formula for Primary and Secondary Processing can also combined together, reducing it to only 2 batches to maintain per day.
b.) Can set any Quantity Values for the Ingredient, Product and By-Product in the Formula details with ANY Cost Allocation (amounting to a total of '1') in the Products section
c.) Set the Validity Rules as 'PRODUCTION' for the 3 Recipes
d.) Complete the steps defined in the 'OPM Cost Management' (as described below)
e.) Create the 2 or 3 batches and record the appropriate quantities at the end of the day before closing the batches
OR should I (Option 2):
a.) Create MULTIPLE Formulas (above 100 formulas) for Primary, Secondary and Further Processing based on the different products processed.
b.) Can set any Quantity Values for the Ingredient, Product and By-Product in the Formula details with ANY Cost Allocation (amounting to a total of '1') in the Products section
c.) Set the Validity Rules as 'PRODUCTION' for the 3 Recipes
d.) Complete the steps defined in the 'OPM Cost Management' (as described below)
e.) Create the MULTIPLE batches and record the appropriate quantities at the end of the day before closing the batches.
b.) OPM Cost Management:
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Whether (Option 1 or Option 2) selected, the below needs to be set for OPM Costing:
a.) Define multiple formulas (above 100), as in Option 2.
b.) Set the Quantity value to be '1' for the Ingredient, Product and By-Product in the Formula details with the appropriate Cost Allocation in the Products section
c.) Set the Validity Rules as 'COSTING' and 'PRODUCTION' for each Recipe
d.) Run Cost Rollup at least once so that the products can have an item cost per unit
As per me, for the purpose of Costing, it would be imperative to have multiple batches (created one time only) with appropriate Cost Allocation in the Formulas and the ‘Recipe Use’ in the Validity Rules should be set as ‘COSTING’. Then, setting Profile Option 'GMF: Use Only Costing Validity Rules for Cost Rollup' to 'Yes'. In this way, we are sure that the different products in the formula with correct Cost Allocation will have their Item Cost calculated after performing the Cost Rollup. AND, for the purpose of operations, we can only one combined formula of Live Birds (as Ingredients) to yield -> All FGs for Primary and Secondary Processing with Cuts. But, this time, the ‘Recipe Use’ in the Validity Rules of the Recipe should be set as ‘PRODUCTION’.
I want to confirm which approach (Option 1 or Option 2) is more appropriate in terms of Operations and confirm that the above proposed steps are correct with no circular reference (as certain finished products are also used as ingredients for another product in the Secondary Processing)?
Thanks and regards
Raveesh Nobeen
[email protected]
Edited by: user12189219 on Jan 20, 2010 3:48 PM

Answer 1

Hi Raveesh
I am implementing OPM R12 in Poultry Processing business, I think option 1 (Create 3 formulas/recipes/batches) is more appropriate. In my case we are using actual costing (Moving Average) as a costing method.
I have set the profile option GMF: Cost Allocation Factor Calculation to be "Dynamic" to calculate the batch cost allocations as a ratio of actual quantity of each product produced to the total production batch output quantity and I have used OPM Financial Cost Allocation process to allocate GL expenses on different products based on Fixed percentage % according to product "value" where Filets has a return more than wings.
Can you please share your knowledge in this business area and confirm to what extend my approach is correct ??
Thank you and best regards
Mamdouh Ragab