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AS400 System IntroductionAS400 System Introduction
Present by HK-ITDPresent by HK-ITD
AS400 SystemAS400 System
AS400 system includes ……
Sales ordering (Sales Confirmation)
Order Details (IO Heading)
BOM (Bill of Materials)
Materials ordering (FPM/FPC, Trims Purchase)
Materials receiving/sending
EDI PO (Polo, Dillard, A&F, Express and etc)
Order costing (IORS – Internal order record sheet)
Production Monitoring (PMS)
Invoicing (FOB, LDP/DDP)
Internal Order (IO) Coding SystemInternal Order (IO) Coding System
Example: T 87008-8, V 61021-M, M 63045MG
Production Month/Special Function (8th digit)
Split IO/GO IO Special Function(7th digit)
Factory Code/Production Line (1st digit)
Customer Code (2nd & 3rd digits)
Customer Order No. (4th to 6th digits)
IO Number is a reference key for all systems in AS400 IO Number is a reference key for all systems in AS400 to refer an unique order from buyer.to refer an unique order from buyer.
Internal Order (IO) Coding SystemInternal Order (IO) Coding System
1st digit means factory code/production line
2nd and 3rd digits refer to the customer code
4th to 6th digits refer to serial internal order no.
7th digit is “-” or special function for GO dummy IO (X or M)
8th digit refers to the garment production month/special function
Code Month Code Description Code Description
1-9 Jan to Sep G GO dummy IO M LTMOC order
O (letter)
October Q Quick Respond
N November W LDP/DDP order
D December X Urgent order
P OPA/Sub-con
Y YTI order
Factory Code/Production LineFactory Code/Production Line
Customer List Customer List (Example for LTG division)(Example for LTG division)
Customer Code
Description Customer Code
Description
8A POLO PARENT LINE KNIT 61 DILLARDS - ROUNDTREE & YORKE SWIMWEAR
8B POLO FOA KNIT 62 DILLARDS - TURNBURY MEN'S KNIT
8C FOA QUICK RESPONSE KNIT 63 DILLARDS - BLUE MEN'S KNIT
8D POLOCO BOY'S AND KID'S 64 DILLARDS - CLASS CLUB KIDS BOY'S KNIT
8E POLO RRL & RLX 65 DILLARDS MEN'S WOVEN
8F FOA QUICK RESPONSE FLEECE 66 DILLARDS WOMEN'S WOVEN
8G POLO WOMEN'S KNIT 67 DILLARDS WOVEN PANTS
8H POLO - MOUNTAIN ROSE KNIT 69 DILLARDS - BECHAMEL LADIES WOVEN
8J POLOCO KNIT D1 DILLARDS - MURANO MEN'S KNIT
8K POLO PARENT LINE QUICK RESPONSE FLEECE
D2 DILLARDS - CARIBBEAN MEN'S KNIT
8L NAIGAI - POLO SPORT JAPAN KNIT D3 DILLARDS - AIGLE MEN'S KNIT
8M POLO WOVEN FOB USA ORDER D4 DILLARDS - TREVERO MEN'S KNIT
8N POLO SPORTSWEAR COLLECTION D5 DILLARDS - DC MEN'S KNIT PANTS
8P POLO KOREA LICENSEE WOVEN D6 DILLARDS - TURNBURY MEN'S WOVEN PANTS
Customer List Customer List (Example for GJM division)(Example for GJM division)
Customer Code
Description Customer Code
Description
3A Victoria Secret Sleepwear Dept. 20/60
3T British Home Stores Sleepwear
3B Victoria Secret Foundation Dept. 25/30
3U Walmart UK Sleepwear
3C Victoria Secret Innerwear Dept. 50
3X CK Men’s Sleepwear
3D Victoria Secret Bra/Panty Dept. 01
3Y CK Women’s Sleepwear
3E Victoria Secret Cotton Dept. 70 3Z Dillards Men’s Sleepwear
3F Avon Sleepwear 7S Limited Too Sleepwear
3G Target Sleepwear 7X A&F Sleepwear
3H Walmart Sleepwear 7Y Express Sleepwear
3J Steinmart Sleepwear 11 Nautica Sleepwear
3K BJ Wholesale Sleepwear 47 Sears Sleepwear
3L ASDA Sleepwear 82 Dillards Fountain
3N Debenhams Sleepwear 87 Dillards women’s Sleepwear
3P D Perkins Sleepwear 97 Kmart Sleepwear
3Q Lasenza Sleepwear CC Dunnes Sleepwear
3R Evans Sleepwear LL Sears Sleepwear
3S Contessa Sleepwear
Internal Order (IO) Coding SystemInternal Order (IO) Coding System
IO No. for ordering sample trims under MRF IO No. for ordering sample trims under MRF (Materials Requisition Form)(Materials Requisition Form)
Example: @ Example: @ VV8A8ASUSU0303 or or ~~ MM8M8MSUSU0505
11stst digit means sample order digit means sample order““@” - regular sample@” - regular sample““~” - LTMOC sample~” - LTMOC sample
22ndnd digit means factory code/production line digit means factory code/production line33rdrd and and 44thth digits refer to the customer code digits refer to the customer code55thth and and 66thth digits refer to the season code or LTMOC digits refer to the season code or LTMOC
““SP” SP” – spring– spring““SS”SS” – spring/summer– spring/summer““SU” SU” – summer– summer““FA” FA” – fall– fall““FW” FW” – fall/winter– fall/winter““CR” CR” – cruise/holiday– cruise/holiday
77thth and and 88thth digits refer to season year digits refer to season year
Internal Order (IO) Coding SystemInternal Order (IO) Coding System
IO No. under IORS (Costing/Pricing)IO No. under IORS (Costing/Pricing)
Example: K Example: K 8A8A210210AA
11stst digit means factory code/production line digit means factory code/production line 22ndnd and and 33thth digits refer to the customer code digits refer to the customer code44rdrd to to 66thth digits refer to serial internal order no. digits refer to serial internal order no.77thth digit means different cost, price, quota cat, destination, digit means different cost, price, quota cat, destination,
payment terms or customer delivery datepayment terms or customer delivery datei.e. “-”, “A” to “Z” for each cost or pricei.e. “-”, “A” to “Z” for each cost or price ““@”@” and and “*”“*” cannot use for it cannot use for it
General Process General Process FlowFlow
TOPMANAGEMENT
VENDORMANAGEMENT
MERCHANDISINGRESEARCH &
DEVELOPMENTMATERIAL
PROCUREMENTLTTC
ReviewSales
Forecast
Businessdevelopment
Productdesign &
development
Source materials
Follow upwith
customer
Review andconfirmorders
Makesamples
Sourceaccessories
Evaluatevendors (FAB
& ACC)
Order Information (AS400 System)
Create BOM
Preparepattern and
samples
Purchaseaccessories
Monitor deliveryof fabrics to
production plant
Reviewvendor
performance
Performance Record (AS400 System)
Approve
Create Accvendormaster
MAT PLANNING &CONTROL
Monitor deliveryof accessoriesto production
plant
Product
Development
Create itemcode
Create Fabvendormaster
Create fabriccategories
Purchasefabric
System relatedSystem related
General Process FlowGeneral Process Flow
ATL LOGISTICS SHIPPING FTY WAREHOUSEPRODUCTION
PLANNINGBULK
PRODUCTIONPRODUCTION
COORDIANTION
Order & Purchase Information (AS400 System)
Financial Information (SAP)
PRE-PRODUCTION
Receivematerials
Checkmaterial
completeness
Requestmaterials
Issuematerial to
bulk
Scheduleproduction
Receivematerials
Sendmaterials
ShippingDocuments
Packgarment
Cut/Sew/Iron
Pre-production
sample
Production Information (AS400)
Issue testfabric rolls
Check IOdetail
completeness
Merchandising Process FlowMerchandising Process FlowPrepare annual sales
forecast
MER-SM
Issue SPO to Sample Shop
MER-MO/MER-MDSR
Submit sample to buyer forreviewMER-M
Sample required?No
Yes
Liaise with buyers, obtainprospective orders
MER-M
New fabricsourcing required?
Prepare Costing Sheet andsend quotation to buyer
MER-M
Changes to order?
Obtain buyer orderconfirmation
MER-M
Assign I/O number for each order
MER-M/ MER-MO
Amend order status
MER-MO/MER-MSDR
Yes
No
Yes
Carry out fabric sourcing
MER-M
Buyer changeorder
information
SalesConfirmation
System
Merchandising Process FlowMerchandising Process Flow
BuyerSpecifications
Review and validate orderspecifications
MER-MO
Transmit I/O file to factory
MER-MDSR
Issue SPO
MER-MO/ MER-MDSR
Prepare BOM
MER-MO/ MER-MDSR
Source and approve fabric
MER-MPrepare and approve samples
Sample Shop
Purchase fabric
MER-M
Arrange approved samples tofactory
MER-MO/ MER-MDSR
Purchase accessories a
PUR staff
Sourcing of fabric required
Update IORS
MER-MOPrepare I/O file
MER-MDSR
Any changes to the order?Review and inform the
concerned parties
MER-M
Monitor factory productionschedule and status
MER-MO/ MER-MDSR
Yes
No
No
Yes
Purchasing Process Flow - FabricPurchasing Process Flow - Fabric
Request for mini-markerfrom LTTC
MER-MO/ MER-MDSR
Fabricspecification
Prepare Fabric PC
MER-MDSRSupplier FileMaintenance
Approve FPC
Authorised Staff
Transmit FPC to vendor
XoTrack/MDSR
Arrange and carry outsite inspection of fabric
QA
Follow up vendor's in-house labtest report
QA
Fabric QualityInspection
Report
Review and evaluate
QA-O
Direct shipmentCo-ordinate with
vendor
MER-MDSR
No
Yes
Passed inspection/labtesting
Defectacceptable
Decide correctiveaction
QA-O
MER-M
No
Issuance of Letter ofGuarantee
QA-OVM-M
Yes
Yes
Vendor submitting in-house labtest report
Yes
No
No
Approve/schedule delivery
MPC
Purchasing Process Flow - Purchasing Process Flow - AccessoriesAccessories
Elaborate purchaserequirements based on
BOM/line items
MER-MO
Material ApprovalMemorandum
Source suppliers andrequest for sample
PUR Staff
Prepare Material ApprovalMemorandum
PUR Staff
Evaluate sample
MER-MO
Issue PC/PO
PUR Staff
Approve PC/PO
PUR-M/ PUR-O
No
Sample approvalrequired?
Follow up on the deliveryof accessories
PUR Staff
OutstandingPurchase
Contract (bydelivery date)
Daily ReceivingReport
No
Yes
Bill of Materials(BOM)
MRF
New accessoriesitems?
Yes
Approve new item code
PUR-M
New SampleRequest Form
Transmit PO to vendor
XoTrack/PUR
System OverviewSystem Overview
Account Payable System (AP)
Sample Production Order (SPO)
Sample Fabric PC (SFPC)
Material Requisition Form (MRF)
Sample FabricReceiving
R&D System
Wet Processing System
Pre-production Stage
Sales ConfirmationProduction Scheduling
Fabric Purchase Memo (FPM)
Bill of Material (BOM)
Order Processing Stage
IO File Status
IO Heading System
Fabric LC SystemFabric Purchase Contract (FPC)
Material Submission (Accessory)
Purchasing SystemMaterial Receiving
Material Sending
Fabric Inspection System
EDI PO SystemProforma Invoice (For POLO only)
Internal Order Record Sheet (IORS)
Garment LC & Open Account System
Material Requisition Form (MRF)
US/UK Sales Office
Material Receiving / Issuance
Production Monitoring System
(PMS)Invoicing System
LDP/DDP Invoicing System
Production Stage
Fabric Cutting System
Sample Fabric Sending
Fabric consume
SAP
SAP SAP
SAP
SAP
Shipment Information
A
A
SAP
Garment & Subcon PO System
Quota Management System
LDP/DDP Monitoring System
SAP
Payment Request System
Fabric Library System
Screen LayoutScreen Layout
Screen TitleScreen TitleSearch fieldSearch field
Options or Functions for this screenOptions or Functions for this screen
Screen ContentScreen Content
Option fieldOption field
Keyboard LayoutKeyboard Layout
[Enter] [Enter] - - Field ExitField Exit means clear the characters after the cursor position and go to the next field means clear the characters after the cursor position and go to the next field
[Ctrl] left[Ctrl] left - - ResetReset means reset the keyboard typing error means reset the keyboard typing error
[Ctrl] right[Ctrl] right - - EnterEnter means confirm the current page input means confirm the current page input
[Tab][Tab] - Go to the next field- Go to the next field
[Shift][Shift][Tab][Tab] - Go to the previous field- Go to the previous field
[F13] to [F24] - Hold the [Shift] key and press [F1] to [F12]. Example: [F1] + 12 = [F13][F13] to [F24] - Hold the [Shift] key and press [F1] to [F12]. Example: [F1] + 12 = [F13]
[F1] = [F13], …….., [F12] = [F24][F1] = [F13], …….., [F12] = [F24]
Send Report to PrinterSend Report to Printer
After generate a report in AS400. The report will store in a pool. We call it “Spool file”. You need to After generate a report in AS400. The report will store in a pool. We call it “Spool file”. You need to type in the AS400 printer device name to send the report to the printer. Normally, press [F10] or type in the AS400 printer device name to send the report to the printer. Normally, press [F10] or [F22] key go to this screen.[F22] key go to this screen.
Options:Options:
2 – Change printer name2 – Change printer name
4 – Delete a report4 – Delete a report
5 – View report on screen5 – View report on screen
6 – Release to printer6 – Release to printer
7 – Reply system 7 – Reply system messagemessage
10 – Start printer10 – Start printer
EndEnd