SERVICE PARTS TRAINING FOR AS400 Tutorial for using the TBB AS400 Parts System Bills of Material,...
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Transcript of SERVICE PARTS TRAINING FOR AS400 Tutorial for using the TBB AS400 Parts System Bills of Material,...
SERVICE PARTS TRAINING FOR AS400
Tutorial for using the TBB AS400 Parts System
Bills of Material, Option Numbers, Assembly Numbers
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TABLE OF CONTENTS• BEFORE YOU START USING AS/400 3• SIGN ON SCREEN INFORMATION 5• USING MANUFACTURING/PRODUCT STRUCTURE (MF/PS) 7• MF/PS HOME SCREEN 11• BREAKING DOWN A COMPLETE BODY B.O.M. 12• SAMPLE BODY B.O.M. 18• COMPONENTS WITHIN BODY B.O.M. MODULES 22• COMPONENTS WITHIN TBB ASSEMBLIES 24• OPTION NUMBER BREAKDOWN 26• EXAMPLES FOR OPTION AND ASSEMBLY BREAKDOWNS 28• BODY TYPE DESIGNATION CODES 44• BODY MODULE CODES 45• BREAKING DOWN A COMPLETE CHASSIS B.O.M. 46• SAMPLE CHASSIS B.O.M. 51• COMPONENTS WITHIN CHASSIS B.O.M. MODULES 56• BREAKING DOWN A CHASSIS OPTION 66• BREAKING DOWN TBB CHASSIS ASSEMBLIES 74• CHASSIS MODULE CODES 78• COMPLETE TBB DESCRIPTIONS ( OP / IV ) 79• EXAMPLES FOR OP/IV 84• CS/IM SEARCH FEATURE 92• CS/IM HOME SCREEN 95• CS/IM WORD SEARCH 96• CS/IM WITH MF/PS TO FIND PART NUMBERS 100• CS/IM WORD SEARCH OPTIONS 103• CS/IM PART NUMBER SEARCH 107• CS/IM OPTION NUMBER SEARCH 112• CS/IM ALTERNATING SEARCH TACTICS 114
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• Before logging into the AS400 system, consult the TBB Dealer Support Portal Registration Screen for information pertaining to the unit that you will be working on.
• The following information will need to be readily available.• 1) ORDER NUMBER• 2) BUS LENGTH• 3) BODY START DATE• 4) CHASSIS START DATE• 5) WHEELBASE
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– 1) ORDER NUMBER 08325
– 2) BUS LENGTH 141YS
– 3) BODY START DATE 3/7/2008
– 4) CHASSIS START DATE 2/13/2008
– 5) WHEELBASE 277
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• OPTION #1 – THOMAS PARTS SYSTEM IS THE ONLY AVAILABLE OPTION.
• (You can disregard the *** Please Remember*** section under the Sign Off information, this was for the old modem hook up)
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• When this screen comes up, you will have 2 options to choose from:• MF – MANUFACTURNING MANAGEMENT• Breakdowns for option numbers, unit bills of material, components for TBB assemblies• OP – CUSTOMER ORDER PROCESSING• Complete descriptions of TBB part numbers
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• For information on part number breakdowns, option breakdowns and unit bills of material,
• TYPE MF (Manufacturing Management)
• PRESS ENTER
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• MF/PS HOMEPAGE• All required information for using this screen can be found on the TBB Web Portal Registration screen.• To use this screen for body Bills of Material you will need the following information from the Registration screen
– 1) ORDER #– 2) BUS LENGTH– 3) BODY START DATESEE ATTACHED SCREEN PRINT OF REGISTRATION INFORMATION SAMPLE UNIT ON NEXT PAGE
REQUIRED FIELDS
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• COMPLETE TBB BODY BILL OF MATERIAL
• REQUIRED FIELDS:• 1) PLANT
– 1 = TBB BODY DIVISION– 2 = TBB C2 DIVISION– 3 = TBB PARTS DIVISION (Recall kits, VON kits etc.)– 5 = TBB CHASSIS DIVISION– 9 = TBB MINOTOUR DIVISION
2) INQUIRY DISPLAYA = AS USED
3) PARENT IDENTIFICATIONORDER NUMBER – BODY LENGTH (For complete body B.O.M.)OPTION NUMBER (Component parts for specific option number)TBB PART NUMBER (Component parts for TBB manufactured parts)
4) ACTIONI = INQUIRY (Only option available)
5) EFFECTIVITY SEARCHBODY START DATE (For complete body B.O.M. and body option numbers)CHASSIS START DATE (For complete chassis B.O.M. and chassis option numbers)
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• UNIT INFORMATION WILL BE LISTED AT THE TOP OF THE PAGE
• All of the modules required to build the unit will be listed.
• Modules are specific to unit type and parts grouping.
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• NOTE: The first B.O.M that appears will generally be the window Bill of Material. Some older units will not have any parts listed under this module. If no windows are listed, contact your TBB Parts Analyst for further information. Occasionally, the Driver Seat will be listed in the 1st or 2nd row of the B.O.M..
• MODULE CODE DESIGNATIONS• The first 4 digits of each module specify the unit type and the parts grouping. The rest of the
number will vary depending on options and sizes.• Each module will include a short description to go along with the designation code
– The first 2 digits will be 0 followed by the body type designation.– I.E. 0Y= HDX / 08 = MVP-EF / 0P = FS65 Conventional
• For a complete list of body designation codes, see the end of this section
– The 3rd and 4th digits will coincide with the specific Body Module Code listings• I.E. 01 = Air Conditioning / 14 = Doors / 30 = Heaters• For a complete listing of all the module codes, see the end of this section.
• EXAMPLE 0Y01EEDI 0Y – HDX UNIT» 01 – AIR CONDITIONING SYSTEM» 0Y06ABA1 0Y – HDX UNIT» 06 - BUMPERS
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The following 4 pages are just a sample of the module bills for unit 08325-141YS.The complete B.O.M. was not printed to save time and space
To navigate through the actual AS400 system: Use PAGE UP or PAGE DOWN key
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• Use the F2 key to exit the B.O.M.
• Use PAGE UP or PAGE DOWN keys to scroll through the modules.
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FINDING COMPONENT PARTS WITHIN THE MODULESTo find component parts within the BOMs and modules:
Tab to desired BOM or moduleTYPE S
PRESS ENTER
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• BOM / Module will open and list all of the assemblies used along with the quantity required, effective start date, effective end date and a description of the part.
• Assemblies within the BOM / Module can be broken down into subcomponents . This does not apply to “vendor supplied assemblies” (i.e. heaters / mirror kits / stop arms / walkgates etc..)]
• Use the PAGE UP / PAGE DOWN keys to move through the module / BOM pages.
• To exit the list PRESS F2
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• To break an assembly down to the component level.
• 1) Tab to desired assembly
• 2) Type S
• 3) Press ENTER
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• The Assembly number will be listed at the top of the page.
• Component parts for the assembly will be listed in the same fashion as the module / BOM
• Part Number / Quantity Required / Effective Start Date / Effective End Date / Description
• To move through the component list, use the PAGE UP and PAGE DOWN keys.
• To exit the list PRESS F2
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BODY OPTION NUMBER BREAKDOWNS
• The AS400 system can be used to breakdown TBB option numbers as well as complete Bills of Material and TBB assembled components.
• To breakdown a TBB Body option number you will need to follow the same steps as before.
– 1) Log onto AS400
– 2) Option 1
– 3) MF – Enter
– 4) PS – Enter
This will bring you to the MF/PS Home screen again.
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IMPORTANT INFORMATION FOR USING OPTION NUMBER BREAKDOWNS IN AS400 SYSTEM
• PLANT: The location will depend on what type of option number you are working with.– PLANT LISTINGS:
• 1 = TBB BODY DIVISION ( EF / ER / CONVENTIONAL / VISTA )• 2 = TBB C2 DIVISION ( C2 )• 3 = TBB PARTS DIVISION ( RECALL KITS / VON KITS )• 5 = TBB CHASSIS DIVISION ( ER / EF CHASSIS PRODUCTION )• 9 = TBB MINOTOUR DIVISION ( MINOTOUR SRW / DRW )
INQUIRY DISPLAY A ( As Used)
PARENT IDENTIFICATION: OPTION NUMBEROption number prefixes determine usage.
B = Body Option (Plants 1 & 9 )C = Chassis Option ( Plant 5)D = C2 Data Code ( Plant 2)M = C2 Combination Code ( Plant 2 )
ACTION INQUIRY I (Inquiry) Only option available
EFFECTIVITY SEARCH = This is NOT a required field to breakdown an option number. We do recommend that you use this field with the start date of the unit. Using the Effectivity Date will delete old / obsolete parts from the BOM.
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• EXAMPLE 1 BODY OPTION NUMBER BREAKDOWN• .
• Fill in Required Fields– PLANT– INQUIRY DISPLAY– PARENT IDENTIFICATION– ACTION– EFFECTIVITY SEARCH – Not required but highly recommended.
• PRESS ENTER
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• Option number and description will be displayed at the top of the page.
• Module Bills of Material will be listed below.
• *NOTICE – Be sure to check the Quantity Used column before proceeding. If there is a Negative sign after the quantity (1.0000-) it is to denote that the parts within that particular module will NOT be used with this particular option.
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• The module number and description will be displayed at the top of the page• Component parts that make up the module will be listed beneath:• Part Number• Quantity Required• Effective Start / End Date• Description
• TO EXIT THE LIST – PRESS F2
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• The module number and description will be displayed at the top of the page• Component parts that make up the module will be listed beneath:• Part Number• Quantity Required• Effective Start / End Date• Description• Use the PAGE UP / PAGE DOWN keys to switch thought the pages of the module. (This
particular module has 3 pages total)• TO EXIT THE LIST – PRESS F2
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SPECIAL NOTE FOR C2 DATA CODES AND BOMS
• When breaking down option numbers or part numbers in Plant 2 (C2 Division),
Always tab down to the part number, type S and PRESS ENTER.
Some parts listed in the C2 BOMs are actually LEVEL 1 assemblies which can not be purchased.
LEVEL 1 assemblies will generally have to be broken down into components to be purchased.
See next pages for examples of C2 Data Codes and LEVEL 1 assemblies listed within a Data Code.
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• EXAMPLE 2 C2 DATA CODE BREAKDOWN• Fill in Required Fields
– PLANT– INQUIRY DISPLAY– PARENT IDENTIFICATION– ACTION– EFFECTIVITY SEARCH – Not required but highly recommended.
• PRESS ENTER
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• The module number and description will be displayed at the top of the page• Component parts that make up the module will be listed beneath:• Part Number• Quantity Required• Effective Start / End Date• Description
• TO EXIT THE LIST – PRESS F2• SEE NEXT PAGE FOR SPECAIL NOTE ON C2 PART #’s and BOMs
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• Data Code will open and list the usual information.• * NOTICE that the description for part 104992 contains the words “LEVEL 1”• Tab down to the part number• Type S• PRESS ENTER
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• The “LEVEL 1” assembly will be listed at the top of the page.• The component parts that make up the assembly will be listed below.• Part Number• Quantity required• Effective Start / End Date• Description• TO EXIT THE LIST PRESS F2
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• The TBB AS400 system can also be used to breakdown TBB assembled components such as door assemblies and side sash assemblies.
• Log onto the TBB AS400 system,• Option 1 and PRESS ENTER• MF Press enter• PS Press enter• MF / PS Home Page appears
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• EXAMPLE 1 TBB ASSEMBLY PART BREAKDOWN• Fill in Required Fields
– PLANT– INQUIRY DISPLAY– PARENT IDENTIFICATION– ACTION– EFFECTIVITY SEARCH – Not required but highly recommended.
• PRESS ENTER
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• The component parts that make up the assembly will be listed below.
• Part Number
• Quantity required
• Effective Start / End Date
• Description
• TO EXIT THE LIST PRESS F2
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BODY TYPE DESIGNATION CODES
• BODY TYPE DESIGNATION CODES• The 4th Digit of the TBB Body Size Designation Will Determine The Unit Body Type• (This # also marks the 2nd digit of Body Modules in Unique BOM’s)• 0 = CONVENTIONAL• 1 = VISTA• 2 = MINOTOUR (NARROW BODY)• 3 = FORWARD CONTROL (ALL-STAR / OSHKOSH CHASSIS)• 4 = MIGHTY MITE FORWARD CONTROL (NARROW BODY)• 5 = SAF-T-LINER ER• 6 = MINOTOUR (WIDE BODY)• 7 = MIGHTY MITE FORWARD CONTROL (WIDE BODY)• 8 = SAF-T-LINER MVP-EF• 9 = MVP-ER• A = M-BODY• B = SCAT (GM CHASSIS)• C = CL960• D = MOTORHOME• E = SCAT (INTERNATIONAL CHASSIS)• F = M-BODY ON REGULAR ER CHASSIS• K = TL960• L = SINGLE REAR WHEEL MONOTOUR (SRW)• M = DUAL REAR WHEEL MINOTOUR (DRW)• P = CONVENTIONAL (FS65 CHASSIS)• R = CL100 (Daimler Chrysler Commercial Bus)• Y= HDX / NEW LOOK ER• T= SAF-T-LINER C2
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SECTION 2
USING THE TBB AS400 SYSTEM TO BREAK DOWN CHASSIS BILLS OF MATERIAL, OPTION NUMBERS AND ASSEMBLIES
• Before logging into the AS400 system, consult the TBB Dealer Support Portal Registration Screen for information pertaining to the unit that you will be working on.
• The following information will need to be readily available.• 1) ORDER NUMBER• 2) BUS LENGTH• 3) BODY START DATE• 4) CHASSIS START DATE• 5) WHEELBASE
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– 1) ORDER NUMBER 08325
– 2) BUS LENGTH 141YS
– 3) BODY START DATE 3/7/2008
– 4) CHASSIS START DATE 2/13/2008
– 5) WHEELBASE 277
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LOGGING INTO THE SYSTEM
• Log into the AS400 system using the process described at the beginning of the tutorial.
• TBB DEALER• TBBDEALER• OPTION 1 Press Enter• MF Press Enter• PS Press Enter• MF / PS Home Screen
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• All of the required information fields needed to break down current chassis Bills of Material can be found on the TBB Web Portal Registration page.
• SEE ATTACHED SCREEN PRINT OF REGISTRATION INFORMATION SAMPLE UNIT ON NEXT PAGE
• When using the AS400 for current chassis Bills of Material, you will need the following information from the Registration page:
• 1) ORDER NUMBER
2) WHEELBASE ** Wheelbase will be listed as a 3 digit number, add 0 to the end.
3) BUS LENGTH ** The 4th digit (Body type designation) will be needed
4) CHASSIS START DATE
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• 1) ORDER NUMBER 08325• 2) WHEELBASE 2770 (always add 0 to end of wheelbase)• 3) BUS LENGTH 141YS ( Y Body Designation Code)• 4) CHASSIS START DATE 02/13/2008
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• COMPLETE CHASSIS B.O.M.• Enter required fields• 1) PLANT 5 ( TBB Chassis Division )• 2) INQUIRY DISPLAY A ( As Used )• 3) PARENT IDENTIFICATION: 08325-2770Y
– 1st Part of Number = Unit Order Number -08325– 2nd Part of Number = Wheelbase + Body designation Code 2770(WB) + Y
• 4) ACTION I• 5) EFFECTIVITY SEARCH 2/13/08 ( Chassis Start Date )• PRESS ENTER
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• The unit information will be listed at the top of the page.
• All of the modules used to build the unit will be listed beneath.
• The first 2 digits of each module will designate the unit type.
• 0Y = HDX
• 08 = MVP-EF
• The 3rd and 4th digits will designate the specific Module Codes.
• For a complete listing of the chassis module designations, see list at the end of this section.
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• To scroll through the pages of the complete chassis B.O.M., – Use the PAGE UP and PAGE DOWN buttons
• To exit the B.O.M.– Press F2
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• Continued SAMPLE PAGES OF CHASSIS BOM.
• This not the complete BOM for this particular unit. All of the Modules were not printed to save time and space
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• To find component parts within the modules of the chassis BOM:• Follow standard steps to get to the MF / PS Home screen• Enter Required Fields
– PLANT– ACTION– PARENT IDENTIFICATION– ACTION– EFFECTIVITY SEARCH
• PRESS ENTER
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• Module List will be displayed with unit information at the top of the page.• Use the Chassis Module Code to quickly find the grouping that you need.
• Tab to the desired Module.• TYPE S• PRESS ENTER
• The next several pages are examples for finding components in Chassis Modules.
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• To find Steering Wheel for this unit.
• PAGE UP / PAGE DOWN until you reach the Steering Wheel module code ( C6).
• TAB down to the module
• TYPE S
• PRESS ENTER
• Module will open listing components for the steering wheel. ( See next page )
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• Steering Wheel = 61320218
• Horn Button = 61320218
• PRESS F2 to exit the module
• *NOTE – You can tab to the 62320492 assembly, type S and this assembly will breakdown also.
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• EXAMPLE 2 AIR CLEANER ASSEMBLY• PAGE UP /PAGE DOWN to Air Cleaner module group ( D2 )• TAB to desired module with the grouping.• TYPE S• PRESS ENTER• Module will open listing components for the steering wheel. ( See next page )
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• EXAMPLE 3 EXTERNAL OIL COOLER• PAGE UP /PAGE DOWN to Transmission Cooler module group ( H6 )• TAB to desired module with the grouping.• TYPE S• PRESS ENTER
• Module will open listing components for the Transmission Oil Cooler (see next page)
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• OIL COOLER = 61190466
• *NOTE – 140840 is listed as an “installation” This is a TBB engineering drawing that shows the installation procedure for the cooler. These can be requested from your Analyst or check TBB Parts Inquiry tab on TBB Online.
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• EXAMPLE 3 FRONT SHOCK ABSORBERS• PAGE UP /PAGE DOWN to Front Shocks module group ( J8 )• TAB to desired module with the grouping.• TYPE S• PRESS ENTER
• Module will open listing components for the Front Shock Absorbers (see next page)
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CHASSIS OPTION NUMBER BREAKDOWNS
• The AS400 system can be used to breakdown TBB option numbers as well as complete Bills of Material and TBB assembled components.
• To breakdown a TBB Chassis option number you will need to follow the same steps as before.
– 1) Log onto AS400– 2) Option 1– 3) MF – Enter– 4) PS – Enter
This will bring you to the MF/PS Home screen again.
*NOTE: Chassis option numbers will be designated the first letter. The first letter in all Chassis options will be “C”. Chassis option numbers can be supplied by your Sales Dept., The TBB shop order option list or the order look up on the TBB Portal
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• EXAMPLE 1 CHASSIS OPTION NUMBER BREAKDOWN• .
• Fill in Required Fields– PLANT 5– INQUIRY DISPLAY A– PARENT IDENTIFICATION OPTION NUMBER– ACTION I– EFFECTIVITY SEARCH – Not required but highly recommended.
• PRESS ENTER
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• The Option Number and description will be displayed at the top of the page.
• Module for the option number will be listed below the description• TAB to Module• TYPE S• PRESS ENTER• Parts within the module will be displayed ( See next page )
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• EXAMPLE 2 CHASSIS OPTION NUMBER BREAKDOWN• .
• Fill in Required Fields– PLANT 5– INQUIRY DISPLAY A– PARENT IDENTIFICATION OPTION NUMBER– ACTION I– EFFECTIVITY SEARCH – Not required but highly recommended.
• PRESS ENTER
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• The Option Number and description will be displayed at the top of the page.
• Module for the option number will be listed below the description• TAB to Module• TYPE S• PRESS ENTER• Parts within the module will be displayed ( See next page )
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***SPECIAL NOTES****
• 1) ALWAYS be sure to check the usage rate (quantity required) for a NEGATIVE ( - ) notation after the quantity. This denotes that the part was removed from the BOM.
• 2) This option number example was entered WITHOUT and effectivity date. The BOM reflects all parts that were ever used with the option. The list includes inactive and no longer used parts. Be sure to check start & end dates on all part numbers.
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BREAKING ASSEMBLIES DOWN TO COMPONENT PARTS
• To break TBB assembled parts down to a component level, you will need to start by following the usual steps to get to the MF / PS Home Screen
• Log In
• OPTION 1 Press Enter
• MF Press Enter
• PS Press Enter
MF /PS Home Screen will appear
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• To breakdown a TBB assembled part:
• Fill in Required Fields– PLANT 5– INQUIRY DISPLAY A– PARENT IDENTIFICATION ASSEMBLY PART NUMBER– ACTION I– EFFECTIVITY SEARCH – Not required but highly recommended.
• PRESS ENTER
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• ASSEMBLY NUMBER AND DESCRIPTION WILL BE LISTED AT THE TOP OF THE PAGE
• Component parts will be listed beneath;• PART #• QTY. REQUIRED• START / END DATE• DESCRIPTION• Use the PAGE UP / PAGE DOWN keys to scroll through the BOM
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SECTION 3
• This section will show how to use the TBB AS400 system to find complete TBB descriptions for part numbers, Option Numbers and Data Codes .
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• This screen will automatically default to Warehouse 3. This can not be changed.
• TO USE THIS SCREEN:
ITEM ID. Enter the Complete part number.• PRESS ENTER
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• ITEM ID. Will be the part number that you entered.
• The first line under the part number will give the basic TBB description for the part.
• The 2nd line will generally give dimensions, colors, right / left notations or other more specific information.
• SEE NEXT SEVERAL PAGES FOR EXAMPLES OF ADDITIONAL INFORMATION AVAILABLE THROUGH THIS SCREEN.
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• Basic Information: 3 Window Side Sheet• Specifically 20 gauge material by 46” tall by 90 ¼” long
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• BASIC INFORMATION Crossview mirror assembly
• Specifically – 1 Complete pair heated with ball stud mount for an IHC Conventional
• TO EXIT: PRESS F3
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• The OP/IV screen can also be used to find the complete description of an option number.
• Will work for body options (B) Chassis options (C) C2 Data Codes (D)
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• Corporate Item Master Screen• Item = Part # / Description / Option Number / Data Code / Word• Actions = B – Browse By Item ID (Part# / Option# / Data Code)
• L – Browse By Item Desc. ( Word / Phrase )
• Selection = G – General Information (Only Option)
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• SEARCH FOR THE WORD DECAL• ITEM DECAL• ACTION L (Browse by Description)• SELECTION G (General Information• ENTER
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• All instances of the word will appear in alphabetical order.• Item Description - Search Parameter (word / description etc…)• Item ID Part Number / Option Number / Module Number / Data Code • Page Up to scroll backwards• Page Down to scroll forward
OPTION #
PART #
MODULE #
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• Module numbers that use the decal “DO NOT BLOCK”• Take the module based on the unit type (0Y / 08 / 0L / 0M / 0P ) and enter it into the
AS400 MF/PS screen to find a part number.
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• Enter the module number into the MF /PS screen in the Parent Identification field.• Inquiry Display A• Action I• ENTER
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• Part numbers listed in search can be used with a TBB prefix.• Option numbers can be broken down using the same process as the modules.
PART NUMBERS
OPTION NUMBERS
109• Adding to the description can help to narrow the search – DECAL – EMERG
“D” Codes =C2 Options
Breakdown in Plant 2
110• You may have to try switching words around. SHEET-SIDE / SIDE SHEET• Part names do not always follow the same format.
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• Use the F1 key to exit the Item Master Search• Use the F2 key to go back to the Item Master Search Screen
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• Search by Part Number• ITEM PART NUMBER• ACTION B Search by Item ID• SELECTION G General Information• Press Enter
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• Numeric sequence search starting with the part number you entered.• Page Up to scroll backwards• Page Down to scroll forwards
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• Numeric Sequence search will include:• Part numbers / Drawing numbers / Schematics / Illustrations / Charts / ETC…
Page Down will continue the search in numeric sequence.
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• You can also search by partial part number.• Enter the first several digits and search.• 612302***** (61=TBB Chassis Part / 23=Engine Accessories Group)
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• SEARCH BY OPTION NUMBER• ITEM OPTION NUMBER (complete or partial)• ACTION B• SELECTION G• Press ENTER 2 times
118• Option numbers listed in sequence• Description of options to help differentiate between unit types and extra options.
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• Start with an Option Number and run a Search.• Copy the description and run a search by description for more information on the
option.
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• Paste the description into the SEARCH line.• Tab down and change the B (Search by ID) to L (search by description)• Press ENTER
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• There are several other uses for the CS / IM search feature.• These are covered in the TBB AS400 PRE UNIQUE B.O.M. TRAINING session