CRYSTAL GROUP L010100 / L010200: Material Master & Bills Of Material (BOM) CEN Training Production...

CRYSTAL GROUP

L010100 / L010200:

Material Master &

Bills Of Material (BOM)

CEN Training

Production Planning

CRYSTAL GROUP

Course Content

• Material Master Concept

•Material Type, Material Group

•Sales Order Vs Style Master

•SO Generated Vs Common Parts

•Program Specific Vs Non-Program Specific Common Parts

•Base UOM Vs Order UOM

•Attributes

•Service & Packing Material

•Material Master Creation using Excel Worksheet

• Bills Of Material Concept

•Definition & Crystal Applications

•Single Level Vs Multi Level BOM

•BOM Creation using Excel Worksheet

•Add-on BOM

CRYSTAL GROUP

Course Content




•SO Generated Vs Common Part

•Program Specific Vs Non-Program Specific Common Part


•Attributes







•Add-on BOM

CRYSTAL GROUP

Material Master Concept

Standardization of the material master system in Crystal so as to: Simplify the searching and identifying on the common parts/ program

common parts in Crystal for: Material planning and list creation and maintenance Inventory Management

Material Movement Allocation of stock to the sale order/program sales Re-allocation of stock when sale order changed

Issuing purchase order of raw material/sub-material

Improve quality of the overall operation and documentation Reporting accuracy and efficiency

Maintain once and all department can share the information

CRYSTAL GROUP

Material Type, Material Group

Material Type Material type is to group together materials with the same basic attributes

Material Group

Material groups are to group together materials for material management analysis and systematically search for material master records

Material NumberNumber uniquely identifying a material master record

CRYSTAL GROUP

Material Type Definition

In Crystal, the definition of material type is to group together materials with the same basic attributes, for example, finished goods, fabric, Yarn, Sub-materials, etc.

When creating a material master record, the material must assign to a material type. The material type determines: Which user department will use the material What procurement type the material has; that is, whether it is

manufactured in-house or procured externally, or both Whether changes in quantity are updated in the material master

record (Plant level) Whether changes in value are also updated in the stock accounts in

financial accounting (Plant level) Which account assignment (valuation class) are used for inventory

and cost update (Plant level)

CRYSTAL GROUP

Material Type in Crystal

Material Type Naming Convention

Keep Inventory

Description

Finished Goods ZCFG Yes Crystal FG

Semi-Finished Good

ZSFG Yes Crystal Semi-FG

Fabric ZFAB Yes Crystal Fabric

Yarn ZYRN Yes Crystal Yarn

Sub-Material ZSUB Yes Crystal Sub-material

Production Supplies

ZPDS No Crystal Production supplies

Trading Assets ZTAT Yes Crystal Trading Assets

Sample ZSPL No Crystal Sample

Service ZSRV No Crystal Service

CRYSTAL GROUP

Material Group Definition

The material group (base material group) is the level in the material group hierarchy that must be assigned directly to a material when it is created. It is defined across the corporate group and sub-divides the complete material assortment from a business management viewpoint.

In a normal way, material groups are to group together materials with the same attributes or purpose.

You can use material groups to:

Select the scope of analyses for material management Systematically search for material master records via matchcodes

CRYSTAL GROUP

Material Group – Naming Convention

Type X XXRAW MATERIAL (WOVEN)Type X X X X X X X XW (R/S) FinishingRAW MATERIAL (KNITTED)Type X X X X X XKRAW MATERIAL (YARN )Type X X XY Spin typeSUB MATERIALType X X XSPRODUCTION SUPPLIESType X X XPTRADING ASSETSAssetsSERVICEZservice

(Weave type)

Garment type

(Fabric Content) (Weight/Wale)

(Yarn Count) (Weave type) (Fabric Content)

(Type)

(Type)

(Sweater Content)

CRYSTAL GROUP

Material Group for Finished Goods/ Semi-Finished Goods

FG = Finished Goods Naming Convention(Material Type) (Garment type)G = Finished Goods MN = MENS

LD = LADIESKD = KIDSBB = BABYAC = ACCESSORIES

X = Semi-Finished Goods Naming convention(Material Type) (Garment type)X = Semi-Finished Goods MN = MENS

LD = LADIESKD = KIDSBB = BABYAC = ACCESSORIES

CRYSTAL GROUP

CAL Material Group – Raw Material

RAW MATERIAL ( Type + WEAVE TYPE + CONTENT + WT / WALES + REGULAR / STRETCH + FINISHING ) Type WEAVE TYPE CONTENT WEIGHT / WALES REGULAR /

STRETCH FINISHING

X XX XX XX X XW = Woven DM = DENIM CC = 100% COTTON LT= LIGHT WT (BELOW 6 OZ) R = REGULAR S = SOLID

TW = TWILL CT = COTTON POLYESTER MD= MEDIUM WT (OVER 6 - 9 OZ) S = STRETCH P = PRINT PL = PLAIN CN = COTTON NYLON HV= HEAVY WT (OVER 9 OZ) Y = YARNDYE VT = VELVETEEN CS = COTTON SPANDEX / LYCRAVV = VELVET TT = 100% POLYESTER PU = PU TC = POLYESTER COTTON PK = POCKETING NN = 100% NYLON KT = KNIT ( SINGLE JERSEY, NC = NYLON COTTON RIB / INTERLOCK,MESH, RC = RAMIE COTTON POLARFLEECE, ETC ) LC = LINEN COTTON LN = LINING OT = OTHERS OT = OTHERS

( FOR CORDUROY ONLY ) CD = CORDUROY 06 = 6 WALES

08 = 8 WALES 11 = 11 WALES 14 = 14 WALES

CRYSTAL GROUP

EIL Material Group – Raw Material

RAW MATERIAL ( Type + YARN COUNT + WEAVE TYPE + CONTENT ) Type YARN COUNT WEAVE TYPE CONTENTX XX XX XXK = Knitted 10 BF = BONDING FLEECE CC = 100% COTTON

16 DI = DROP NEEDLE INTERLOCK CS = COTTON / SPANDEX OR LYCRA18 DR = DROP NEEDLE RIB TC = POLYESTER COTTON20 DV = DROP NEEDLE VELOUR TT = POLYESTER24 FK = FLAT KNIT COLLAR / CUFF PY = POLYESTER RAYON26 FL = FLEECE PS = POLYESTER SPANDEX30 FR = FRENCH RIB RS = RAYON SPANDEX32 FT = FRENCH TERRY CN = COTTON NYLON36 IN = INTERLOCK PA = POLYESTER ACRYLIC40 IP = INTERLOOP PV = POLYESTER VISCOSE50 JQ = JACQUARD60 LA = LACOSTE

LI = SPANDEX INTERLOCKLJ = SPANDEX JERSEYLL = LYCRA LACOSTELP = SPANDEX PIQUELR = SPANDEX RIBLW = SPANDEX WAFFLERME = MESHMF = MICRO FLEECE PC = POPCORNPF = POLAR FLEECEPQ = PIQUERB = RIBPR = PONTIDE ROMASJ = SINGLE JERSEYTR = TOWEL TERRYTP = TWILL TAPEVL = VELOURWA = WAFFLE

CRYSTAL GROUP

CSL Material Group – Raw Material

RAW MATERIAL ( Yarn + Spin Type + Content ) Yarn Spin Type ContentX X XXY = Yarn W = Woolen AA = Acrylic HA = Shetland Acrylic RW = Ramie Wool

R = Worsted AC = Acrylic Cotton HH = Shetland RX = Assorted MaterialF = Fancy AD = Dry Acrylic HW = Shetland Wool RY = Ramie Rayon

AH = Acrylic Shetland IA = Linen Acrylic SA = Silk AcrylicAK = Wool Like Acrylic IC = Linen Cotton SC = Silk CottonAN = Acrylic Nylon II = Linen SC = Silk CottonAO = Polypropylene Acrylic IY = Linen Rayon SG = Silk AngoraAW = Acrylic Wool LA = Lambswool Acrylic SN = Silk NylonCC = Cotton LL = Lambswool SS = SilkCT = Cotton Polyester LN = Lambswool Nylon SY = Silk RayonCY = Cotton Rayon MM = Mohair TN = Polyester NylonEC = Cashmere Cotton NC = Nylon Cotton TT = PolyesterEE = Cashmere NN = Nylon VV = LycraES = Silk Cashmere OO = Polypropylene WA = Wool AcrylicGG = Angora QN = Rayon Nylon WL = LambswoolGL = Angora Lambswool RA = Ramie Acrylic WN = Wool NylonGN = Angora Nylon RC = Ramie Cotton WW = WoolGY = Angora Rayon RR = Ramie YY = Rayon

ZZ = Metallic

CRYSTAL GROUP

Material Group for Sub-material

Submaterial = Material type + Material groupMaterial Type Material Group/ NamingX XXXS = Sub Material Label LAB Sticker STR

Patch PAT Plastic Clip PCPButton BTN Rhinestone RSERivets RIT Heat Transfer HTREyelets EYE Lace LACElastic band ELD Polybag PBGThread THD Nylon Pin NPNZipper ZIP Adhesive tape ATEShoulder Tape STE PVC Tape TPEShoulder pad SPD Packing Tape PTEVelcro tape VTE Cardboard CBDBelt BLT Tissue Paper TPRBow BOW Carton CTNDrawstring DSG Sundry SDYCord CRDTape TPEInterlining ITGHanger HGRSizer SZRHanger hook HOKHook & Eyes HESHook & Eyes tape HETBuckle BUETags TAG

CRYSTAL GROUP

Material Group for Production supplies

Production supplies = Material type + Material groupType Material Group NamingX XXXP=Production Cutting consumables PCCSsupplies Cutting equipment parts PCEP

Sewing consumables PSCSSewing chemicals PSCHSewing equipment parts PSEPWashing consumables PWCSWashing chemicals PWCHWashing equipment parts PWEPFinishing consumables PFCSFinishing chemicals PFCHFinishing equipment parts PFEPPacking consumables PPCS

CRYSTAL GROUP

Course Content







•Attributes







•Add-on BOM

CRYSTAL GROUP

Sales Order Vs Style (Finished Goods) Number

5 P 03 02 001

Division:3 – Sweater5 – Elegance6 – Apparel

CO:Eg. P – PRC S – SRI LANKA M – MONGOLIA

Year:03 – 200304 – 2004

:

Month:01 – Jan

:12 - Dec

Sequential number:001 -999

Style (Finished Goods) Number = Sales Order Number

CRYSTAL GROUP

Sales Order Generated Vs Common Part

Two Main Categories for Component: Common Parts

Definition : Material that are purchased for shared use including bulk purchase and purchase without sales orders

Sales Order Generated Parts Definition : Materials that are purchased because of sales order requirement

Material Type Common Parts Sales Order Generated Parts

Semi-FG N/A (eg. 5P0302001-P01)

Fabric (eg. FDM0012) (eg. 5P0302001-F01)

Yarn (eg. Y0008) (eg. 5P0302001-Y01)

Sub-Material (eg. STHD0034) (eg. 5P0302001-S01)

Production supplies N/A N/A

Trading Assets (eg. TA3010310002541) N/A

Sample N/A N/A

Remark: - Applicable

CRYSTAL GROUP

SO Generated Part – Naming Convention

5 P 03 02 001

Division:3 – Sweater5 – Elegance6 – Apparel

CO:Eg. P - PRC

Year:03 – 200304 – 2004

:

Month:01 – Jan

:12 - Dec

Sequential number:001 -999

01-

Sequential number:

01 -99

F

Material Type:F – FabricY – YarnS – Sub-Mat’lP / T / B – Semi FG

CRYSTAL GROUP

Common Parts – Naming ConventionProgram Specific Vs Non Program Specific

Material TypeParts number syntax

Part number structure Example

F DM 0012 = Denim 55% Ramie 45% Cotton

F TW 0005 = Twill 70% Cotton 30% Wool

Yarn Y 9999 (Y + running number) Y 0008 = 2/32 100% Cotton

Sub material S XXX 9999 (S + Type + running number) S THD 0034 = Thread (Cotton)

Trading AssetTA XXXX 99999999 9

(TA + Company Code + running number)

TA 3010 31000254 1 = Leasehold Improvement

Fabric F XX 9999(F + Weave Type + running number)

CAL EIL CSL

Sample

Service

A sequential number shared with 3 companies (0000000001 - 9999999999)

Division + Country of Origin + Service Type (E.G. 3PWASHING)

Program Specific Common Parts:•Materials which being used WITHIN the Sales Program•Material Colors defined according to the Sales Program

Non-Program Specific Common Parts:•Materials which being used BETWEEN Sales Orders / Programs•Material Colors pre-defined

CRYSTAL GROUP

Base UOM Vs Order UOM

Two Main Unit of Measures used in Garment Industries: Base UOM

Definition : Units of measures that used in Stock Keeping & Consumption Calculation. Normally the smallest unit for the material specified

Order UOM Definition : Unit of measures that used in Purchasing and Order placing to

Vendors and Receiving goods from Vendors.

Base UOM Order UOM Conversion Factor Examples

YD (Yard) LB (US Pounds) 1 LB = 0.9144 YD Knit Fabric

IN (Inch) YD (Yard) 1 YD = 36 IN Adhesive Tape

M (Meter) YD (Yard) 1 YD = 0.9144 M Shoulder Tape

M (Meter) CON (Cone) 1 CON = 5000 M Thread

PC (Pieces) GRS (Gross) 1 GRS = 144 PC Button

PC (Pieces) DZ (Dozen) 1 DZ = 12 PC Tag

PC (Pieces) KPC (Kilo Pieces) 1 KPC = 1000PC Label

In view of the different UOM requirements, the following Conversion Factors are EXAMPLES that maintained in Material Master:

CRYSTAL GROUP

Course Content







•Attributes







•Add-on BOM

CRYSTAL GROUP

Attributes (Classification) Concept

General requirement in SAP

The SAP classification system is a tool offering functions more fast searching than matchcodes or systematically assigned number, to help you set up the kind of organization you need.

The main purpose of the classification system is to bring order to an attribute of objects. It is easier to find objects if they are organized and described in a structured way.

Expectation in Crystal

In Crystal, the classification system should allow us to group material with the same characteristics.

So that, we can base on characteristic to SEARCH material and provide structured way to perform ANALYSIS for management.

In addition, to STANDARDIZE Description for Material Master, it would be comprised from combination of characteristic values.

CRYSTAL GROUP

Attributes (Classification)Application

Material Type Description Combination Attributes Full List

Finished Goods

PRODUCT DIVISION + CONTENT + KNIT TYPE + PRODUCT

Semi Finished Goods

PRODUCT DIVISION + CONTENT + KNIT TYPE + PRODUCT

Fabric (Knit) YARN COUNT + GROUP + FIBRE CONTENT + FINISHING + ARTICLE NO

Fabric (Woven) ARTICLE NO + FIBRE CONTENT + TYPE + FINISHING + CONSTRUCTION + YARN COUNT

Yarn YARN COUNT + YARN CONTENT

Sub-Material 1) CONTENT + GROUP + ARTICLE NO

2) GROUP + ARTICLE NO

3) TYPE + GROUP ……

CRYSTAL GROUP

Course Content







•Attributes







•Add-on BOM

CRYSTAL GROUP

Service & Packing Material Service Master application in Crystal

In Crystal, it is often that Finished Goods / Raw Materials require special treatment / processing before sell to our customers.

In the view of this requirement, we use the Material Master Concept to “Purchase” intangible services from Own Factories / Subcontractors when service cost is bear by Crystal HK.

In the case of the service cost bear by Factory, NO Service Master would be used. Instead, we will use ZSERVICE Material Group to indicate this PO is for Service Purchase.

Packing Material application in Crystal

In Crystal, various “Packing” materials are used to suit requirements from Customers. Numerous packing materials & methods render overall maintenance difficult and cost-ineffective.

To solve this, Generic Packing Material is then used to provide a general idea to our Purchasing staff for those requirements.

CRYSTAL GROUP

Service & Packing Material Example

Service Type

Material Group

Material Master

Description

Washing ZSERVICE 6KWASHING Apparel Washing Service (Mauritius)

Beading ZSERVICE 5PBEADING Elegance Beading Service (PRC)

Embroidery ZSERVICE 3SEMBROD Sweater Embroidery Service (Sri Lanka)

Packing Material Group

Material Master

Description

Pre-Pack Sticker

SSTR PPCKSTKER Pre-Pack Sticker (Generic)

Carton Label

SCSL CTNLABEL Carton Label (Generic)

Transparent Tape

STPE TRANSTAPE Transparent Tape (Generic)

CRYSTAL GROUP

Course Content







•Attributes







•Add-on BOM

CRYSTAL GROUP

MM / BOM Upload process overview

Sales Dept Sample/BOM Dept MC Dept

Quotation confirmation

Sample confirmation

Data for materialparts creation

Search/creatematerial parts

List of componentsto be used in BOM

Create BOMStructure in add-on

BOM

Copy uncolored consumptions to confirmed colors

in add-on BOM

Create SM

Color confirmation

Maintain colorconversion

values

Create productionBOM

Update productionBOM

Maintain uncoloredSize-wise

consumptions in add-on BOM

A

M

Automated Process

Manual Process

M

A

M A

A

A

M

M

A

A

A M

(1)Style master

upload

(2)Material parts

upload

(3)Material BOM

upload

CRYSTAL GROUP

Material Master creation using Excel Worksheet

Excel workbookQuotation SMProgramPlant Division

Description M.Grp A1 … Fabric X DM 002 Button BTN B01

Check for existing parts by attributes

SO specific

Program specific

Create SO specific part with generic

color grid

Create program

specific part with generic

color grid

Create common part

with pre-defined color

grid

Yes

Yes

No

No

A

M

Automated Process

Manual Process

M

AM

M

A

A

A

M

M

M

Excel Workbook is a tool for this process but NOT for records!!

CRYSTAL GROUP

Course Content







•Attributes







•Add-on BOM

CRYSTAL GROUP

Bill Of Materials (BOM) Definition and Usage

A formally structured list of the components that make up a product or assembly. The list contains the object number of each component, together with the quantity and unit of measure.

BOMs are used in their different forms in various situations where a finished product is assembled from several component parts or materials.

In Crystal, the BOM purpose is mainly for :

Materials Requirement Planning (MRP) Material consumption and movement control Complete list and check list based on the sales order material

requirement

CRYSTAL GROUP

Single Level Bill Of Materials (BOM)

Type : - General case - Pack case - Suit case (Production in same division)

Finished Goods

Sub-materials

Raw materials

CRYSTAL GROUP

Single Level Bill Of Materials (BOM) – Cont’d

Type : - Suit case (Production in different divisions)

Finished Goods

Sub-materials

Raw materials

Top / Bottom

CRYSTAL GROUP

Multi Level BOM

Type : - Material Subcontracting purpose

Finished Goods

Sub-materials

Twisted Yarn

Yarn Yarn

CRYSTAL GROUP

Multi Level BOM – Cont’d

Type : - OPA Process 2 steps

Finished Goods

Sub-materials

YarnsPanel

Yarn Sub-materials

CRYSTAL GROUP

Multi Level BOM – Cont’d

Type : - OPA Process 2 steps + Material Subcontracting purpose

Finished Goods

Sub-materials

YarnPanel

Twisted Yarn

Sub-materials

Yarn Yarn

CRYSTAL GROUP

Bill Of Materials (BOM) Content

Finished Goods Material Type BOM included

Finished Goods

Semi-Finished Goods

Fabric

Yarn

Sub-Materials

X

X

X

X

X

CRYSTAL GROUP

Course Content







•Attributes







•Add-on BOM

CRYSTAL GROUP

MM/BOM creation process overview

Sales Dept Sample/BOM Dept MC Dept

Quotation confirmation

Sample confirmation

Data for materialparts creation

Search/creatematerial parts

List of componentsto be used in BOM

Create BOMStructure in add-on

BOM

Copy uncolored consumptions to confirmed colors

in add-on BOM

Create SM

Color confirmation

Maintain colorconversion

values

Create productionBOM

Update productionBOM

Maintain uncoloredSize-wise

consumptions in add-on BOM

A

M

Automated Process

Manual Process

M

A

M A

A

A

M

M

A

A

A M

(1)Style master

upload

(2)Material parts

upload

(3)Material BOM

upload

CRYSTAL GROUP

Excel Upload & Add-on BOM Maintenance

Automated

Component List for BOM with average

consumption for components

Maintain BOM Structure in

add-on BOM

Maintain Size-wise consumption for SM/Component

uncolored grid value

Copy uncolored size-wise consumption to

new color grids

Automated Maintain Prod. BOM

Manual

Manual

Excel SAP

In case of color-wise consumption, standard SAP function will be used to cater this variance

BOM Creation using Excel Worksheet

BOM Status Indicator is maintained to indicate the BOM readiness

CRYSTAL GROUP

Thank you for your attention

Proceed to Step by Step Demonstration Session

CRYSTAL GROUP L010100 / L010200: Material Master & Bills Of Material (BOM) CEN Training Production...

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Transcript of CRYSTAL GROUP L010100 / L010200: Material Master & Bills Of Material (BOM) CEN Training Production...