AS400 System Introduction Present by HK-ITD. AS400 System AS400 system includes …… Sales ordering (Sales Confirmation) Order Details (IO Heading) BOM

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.


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


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


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