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
• Material Master Concept
•Material Type, Material Group
•Sales Order Vs Style Master
•SO Generated Vs Common Part
•Program Specific Vs Non-Program Specific Common Part
•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
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
• Material Master Concept
•Material Type, Material Group
•Sales Order Vs Style Master
•SO Generated Vs Common Part
•Program Specific Vs Non-Program Specific Common Part
•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
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
• Material Master Concept
•Material Type, Material Group
•Sales Order Vs Style Master
•SO Generated Vs Common Part
•Program Specific Vs Non-Program Specific Common Part
•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
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
• Material Master Concept
•Material Type, Material Group
•Sales Order Vs Style Master
•SO Generated Vs Common Part
•Program Specific Vs Non-Program Specific Common Part
•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
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
• Material Master Concept
•Material Type, Material Group
•Sales Order Vs Style Master
•SO Generated Vs Common Part
•Program Specific Vs Non-Program Specific Common Part
•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
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
• Material Master Concept
•Material Type, Material Group
•Sales Order Vs Style Master
•SO Generated Vs Common Part
•Program Specific Vs Non-Program Specific Common Part
•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
• Material Master Concept
•Material Type, Material Group
•Sales Order Vs Style Master
•SO Generated Vs Common Part
•Program Specific Vs Non-Program Specific Common Part
•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
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
• Material Master Concept
•Material Type, Material Group
•Sales Order Vs Style Master
•SO Generated Vs Common Part
•Program Specific Vs Non-Program Specific Common Part
•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
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
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