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Piecework [Incentive] Payroll

Visual AS/AP™

AS/AP Apparel Software Phone 770/993-4141 · Fax 770/993-2868

Email [email protected] · Web Site www.visualasap.com

DISCLAIMER Computer software programs cannot replace sound business judgment or make decisions for you. You, therefore, assume complete responsibility for any decisions made or actions taken based on information obtained using ASAP of Georgia, Inc. software programs and instructional materials. ASAP of Georgia, Inc. software and accompanying instructional material are sold "AS IS," without warranty as to their performance. You assume the entire risk as to quality and performance of the software programs and instructional material. ASAP of Georgia, Inc. makes no representations or warranties with respect to the contents or use of this manual, and specifically disclaims any express or implied warranties of merchantability or fitness for any particular purpose. Further, ASAP of Georgia, Inc. reserves the right to revise these publications and to make changes to their content, at any time, without obligation to notify any person or entity of such revisions or changes. ASAP of Georgia, Inc. makes no representations or warranties with respect to any AS/AP™ software, and specifically disclaims any express or implied warranties of merchantability or fitness for any particular purpose. ASAP of Georgia, Inc. reserves the right to make changes to any and all functions and/or specifications of AS/AP™ software, at any time, without obligation to notify any person or entity of such changes.

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INTRODUCTION

AS/AP™ PIECEWORK PAYROLL

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INTRODUCTION This manual is intended for users who understand the concepts of basic accounting and bookkeeping as well as those of their company and who are familiar with the basic operations of their computer hardware and operating system. All of the AS/AP™ manuals have been structured around the assumption that the user understands the basic conventions of the AS/AP™ program as described in the System Utilities Manual.

Documentation Conventions: Before you start using this guide and the online Help system, it’s important to understand the documentation conventions. When you see this… Do this… <Y> A specific key – In this case press the letter Y on your keyboard. <U-1-2> Menu option - In this case select the Utility menu, option 1 then option 2. When not assigned a specific Hot Key function within a program module, the following conventions are in effect: When you see this… Do this… <F10> Function key #10 – Used to jump through an entire input screen without making

changes. <Esc> Press the Escape key on keyboard from most menus and the program will back up

one menu. <Enter> Press the Enter or Return key from the keyboard. <Ctrl> Used in conjunction with another key. <Ctrl><Y> indicates that the user is to press

the Control key and the letter Y at the same time. <PgDn> Page Down key on keyboard. <Ins> The Insert key will toggle the insert function on and off, when on information

entered on the keyboard will overwrite what already exists. <Del> The Delete key will delete the character under the cursor. The following conventions are used throughout the AS/AP™ Manuals and Help System: When you see this… This is…

A note or tip.

An alert or warning.

Custom modifications.

Refer to another manual.

INTRODUCTION

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Printer Interface: The Printer Dialog Box that appears when the user approaches a printer-controlled function can be seen below:

From here you can change the printer name, the default font, font size, lines per page, the file name, as well as sending the data to the printer or the screen. The user can now easily select the font size for the report (or leave the default size which has been selected for the report). The page length can also be easily adjusted to avoid lengthy print jobs or cutting off reports halfway through the page (try different lengths to get the page printed the way your would like). If the user wishes to send the report to the screen they only need to press the Send to Screen button. The screen will then clear and allow the user to select the file location for the report. A default location/path is generally designated allowing the user to simply press the <Enter> key. The report will then be displayed allowing the user to view it without having to print. NOTE: THE PRINT SCREEN OF THE REPORT/FORM IS MERELY A PREVIEW OF WHAT THE USER WOULD RECEIVE FROM THE PRINTER AND THEREFORE IS FORMATTED BASED ON THE SETTINGS FOR THE WORKSTATIONS DEFAULT PRINTER. If a hardcopy of the report is needed the user will press Send to Printer from the Printer Dialog Box in order to print the report. In addition, you may also choose to cancel the report you are about to view in which case you would choose the Cancel Report button.

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Hot Links For your convenience, the most used programs in the AS/AP system have a direct route instead of going through the menus on the toolbar. This ‘Hot Link’ bar underneath the Main Toolbar on the Main AS/AP screen is shown below for your reference:

Each of these links will direct you to the corresponding program. THESE ‘HOT LINKS’ ARE NOT AVAILABLE WHEN THE PROGRAMS ARE OPENED THROUGH THE TOOLBAR.

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TABLE OF CONTENTS


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TABLE OF CONTENTS

INTRODUCTION....................................................................................................................................... 3

TABLE OF CONTENTS ........................................................................................................................... 7

PIECEWORK PAYROLL OVERVIEW ............................................................................................... 11 Rate Basis............................................................................................................................................ 12 Work Codes/Off-Standard Codes........................................................................................................ 12

PIECE WORK TICKETS ....................................................................................................................... 15 RATE BOOK MAINTENANCE.................................................................................................................... 15 GARMENT BREAKDOWN MAINTENANCE................................................................................................ 18

Maintain Garment Breakdowns .......................................................................................................... 19 List Styles with Common Operation.................................................................................................... 22 Insert Operation in Multiple Styles ..................................................................................................... 24 Change Operation in Multiple Styles.................................................................................................. 24 Delete Operation in Multiple Styles.................................................................................................... 25 Delete Obsolete Breakdowns .............................................................................................................. 25 Pack and Reindex Breakdown File ..................................................................................................... 26 Update Style Master File Costs .......................................................................................................... 26 Update Raw Material Master ............................................................................................................. 26 Material Code Table ........................................................................................................................... 27

BUNDLE SHEET DATA............................................................................................................................. 27 ASSIGN NUMBERS AND PRINT TICKETS.................................................................................................. 30 REPRINT PW TICKETS............................................................................................................................. 32 PLACE CUT INTO WORK.......................................................................................................................... 33 PW TICKET REPORTS.............................................................................................................................. 33

Rate Book (Operations) ...................................................................................................................... 34 Garment Breakdown ........................................................................................................................... 35 Bundle Sheet (Tickets)......................................................................................................................... 36 Bundle Check Off List ......................................................................................................................... 36 Work-in-Process by Style .................................................................................................................... 37 Work-in-Process by Cut/Lot................................................................................................................ 37 Work-in-Process by Operation ........................................................................................................... 38 Work-in-Process Summary ................................................................................................................. 39 Graphic – WIP by Cut/Lot .................................................................................................................. 39 Work Pool by Style.............................................................................................................................. 39 Work Pool by Cut/Lot ......................................................................................................................... 40 Work Pool by Operation ..................................................................................................................... 40 Work Pool Summary ........................................................................................................................... 40 Operation Code Performance............................................................................................................. 40 WIP Labor Valuation.......................................................................................................................... 41

BUNDLE MAINTENANCE FUNCTIONS...................................................................................................... 41 Delete Completed/Unused Tickets ...................................................................................................... 42 Adjust Bundle Count ........................................................................................................................... 43 Change Operation on Ticket ............................................................................................................... 43 Scan Unpaid Tickets ........................................................................................................................... 45

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Void a Ticket ....................................................................................................................................... 46 Quality Control Adjustments............................................................................................................... 46 Change Inventory Status ..................................................................................................................... 46 Factory/Plant Assignment................................................................................................................... 47 Transfer CO to Factory ...................................................................................................................... 47 Import Exchange Data........................................................................................................................ 47

WORK-IN-PROCESS SCHEDULING ........................................................................................................... 47 Enter Data to Schedule File................................................................................................................ 48 Edit Requirements/Schedule File ........................................................................................................ 49 List Requirements/Schedule File......................................................................................................... 50 Reset Production Requirements .......................................................................................................... 50 Edit Production Schedule Dates ......................................................................................................... 50 Calculate and Print Schedule ............................................................................................................. 51 Print Production Schedule Only ......................................................................................................... 51 WIP Schedule and Labor .................................................................................................................... 52 Print Labor Requirements................................................................................................................... 52 Recalculate Labor Requirements ........................................................................................................ 54 Rebuild Index Keys ............................................................................................................................. 54

CUTTING INCENTIVE MAINTENANCE...................................................................................................... 55 BUNDLE TICKET OPTIONS....................................................................................................................... 55 STATISTICAL QUALITY CONTROL........................................................................................................... 55

PIECE WORK PAYROLL...................................................................................................................... 56 ENTER DAILY GROSS PAY DATA ............................................................................................................ 56

Overtime Premium.............................................................................................................................. 56 VACATION/HOLIDAY/SICK PAY.............................................................................................................. 59 RESET/DELETE PAYROLL DATA ............................................................................................................. 60 AVERAGE EARNINGS REPORTS ............................................................................................................... 61

Six-Week Running Average................................................................................................................. 61 Four-Week Running Average.............................................................................................................. 62 Quarterly Averages ............................................................................................................................. 62 Thirteen-Week Running Average ........................................................................................................ 63 Edit Averages ...................................................................................................................................... 63 Quick Average Update ........................................................................................................................ 64 Initial System Setup............................................................................................................................. 64 Add/Edit Payroll Subsidy.................................................................................................................... 64 Recalculate Last Quarter Average...................................................................................................... 65

GROSS PAY REGISTER (SUMMARY) ........................................................................................................ 65 GROSS PAY ANALYSIS (DETAILED) ........................................................................................................ 66 EARNINGS BY OPERATOR........................................................................................................................ 67 COUPON REGISTER BY OPERATOR.......................................................................................................... 68 PRODUCTION SUMMARY REPORT ........................................................................................................... 69 EFFICIENCY WEEK-TO-DATE .................................................................................................................. 71 EXCEPTION PAY BY OPERATOR .............................................................................................................. 72 WEEKLY PROCESSING............................................................................................................................. 72

Recalculate Week-to-Date Makeup..................................................................................................... 73 Weekly Overtime Exception List ......................................................................................................... 73 Automatic Overtime Calculation ........................................................................................................ 74 Gross Pay Register [Summary] .......................................................................................................... 75 Detailed Weekly Payroll Analysis....................................................................................................... 75 Export (Bridge) Payroll to ADP ......................................................................................................... 76

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Update Gross-to-Net Payroll File....................................................................................................... 76 BUNDLE MAINTENANCE FUNCTIONS...................................................................................................... 77 CAPACITY PLANNING.............................................................................................................................. 77

Capacity Planning Weekly Report ...................................................................................................... 77 Modify Capacity Plan Schedule.......................................................................................................... 78 List Capacity Plan Schedule ............................................................................................................... 79 Capture Past Payroll Data ................................................................................................................. 80 Report Excess Dollars by Category .................................................................................................... 80

VERIFY COUPON STATUS........................................................................................................................ 81 VAC/HOL/SICK SUMMARY REPORT........................................................................................................ 83 CUTTING/WAREHOUSE INCENTIVE ENTRY............................................................................................. 83

PIECE WORK UTILITIES..................................................................................................................... 84 Payroll Printer Codes ......................................................................................................................... 84

BUILD PAYROLL INDEXES....................................................................................................................... 86 BUILD PIECEWORK INDEXES................................................................................................................... 86 PW SYSTEM FILE UPDATE...................................................................................................................... 87 PACK AND REINDEX FILES...................................................................................................................... 87 LABOR COST ANALYSIS.......................................................................................................................... 88 PURGE CANCELLED TICKETS .................................................................................................................. 88 PIECE WORK OP CODES/TRAINING ALLOWANCE CHART ...................................................................... 89 MACHINE DOWNTIME ANALYSIS............................................................................................................ 94 EDIT BASE RATE TABLE(S) ..................................................................................................................... 94 BAR CODE PRINTER TEST ....................................................................................................................... 95 COMPANY DEFAULTS.............................................................................................................................. 95 UPDATE EMPLOYEE DEPARTMENTS ....................................................................................................... 96 PURGE OLD DATA................................................................................................................................... 96 RUN PW FILE INTEGRITY TEST............................................................................................................... 96 UPDATE DATA FILES............................................................................................................................... 96

APPENDIX A: PIECE WORK PAYROLL RATES............................................................................. 98

APPENDIX B: ALTERNATE OPERATIONS.................................................................................... 100

APPENDIX C: IMPLEMENTATION GUIDE ................................................................................... 104 Overview ........................................................................................................................................... 104 System Components .......................................................................................................................... 104 Rate Book .......................................................................................................................................... 104 Product/Garment Breakdown ........................................................................................................... 104 Piece Work Coupons......................................................................................................................... 105 Piece Work Calculation .................................................................................................................... 105 System Startup................................................................................................................................... 106 Startup Piece Work ........................................................................................................................... 106 Replace Old System Working Properly............................................................................................. 108 Replace Manual System .................................................................................................................... 110

APPENDIX D: PIECE WORK TICKET OPTIONS.......................................................................... 112

APPENDIX E: TIME AND ATTENDANCE....................................................................................... 114

APPENDIX F: SUPERVISOR BONUS................................................................................................ 116

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APPENDIX G: PIECE WORK PROCEDURES................................................................................. 118

PIECEWORK OVERVIEW


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PIECEWORK PAYROLL OVERVIEW The AS/AP™ Piece Work Payroll program is an easy to use system for entering piece work ticket information, daily gross pay data, calculating payroll costs for piece work employees and generating a wide variety of piece work and standard reports. Typically the piecework payroll system begins with the development of your company’s rate book. From there the user can enter garment breakdowns and even complete a garment labor cost sheet, if desired. The bundle ticket information is next. This enables the ticket printing. After printing the piecework tickets and placing them into work, the user can enter the hourly pay data (for piece work employees) either on a daily basis or at the end of a pay period. If the AS/AP™ Gross-to-Net Payroll system is running, the 'hours file' is processed using User Maintainable Tax Tables to calculate Federal, State and Local deductions. A printout of the payroll can be viewed (and edited) prior to printing payroll checks. Lastly, AS/AP™ prints the payroll checks (using the same checks which the payables module uses), updates the employee personnel file, and the General Ledger (if activated). An important feature of the interface between the AS/AP™ Piece Work and Gross-to-Net Payroll programs is the ability to begin a new Piece Work Payroll week before completing the check in the Gross-to-Net program. Instructions for entering and editing employees can be found in Employee Maintenance in the Gross-to-Net Payroll manual. This is necessary whether or not the Gross-to-Net portion of the payroll is running. THE SYMBOLS ‘ “ ! SHOULD NEVER BE USED IN CODES (CUSTOMER CODE, VENDOR CODE, ORDER NUMBER, ETC.) ALTHOUGH WE DON'T BLOCK THEIR USE IN ORDER INSTANCES, THE QUOTES SHOULD NEVER BE USED IN ANY DATA SITUATION. The Piecework Payroll menu is reached by moving the Light Bar left or right until the following ‘Payroll’ menu appears. Notice that the Piecework Payroll functions are the last three options.

The payroll system can be run several ways - independently of the rest of AS/AP™, in conjunction with the General Ledger, or as part of the fully integrated system. The operator can lookup Employee Names on most screens by pressing the <F7> key instead of entering an employee code. The standard Selection Window will open and permit searches for the string of

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characters selected that appear in the employee name or city. The <F6> function key can also be used to lookup an employee by Social Security number. The Piece Work System is broken into three sections to optimize operational speed and provide continuity. Each of these areas is simple and straight-forward in itself, but, only meaningful when taken as a whole. The power of the Piece Work System is the interrelationship between these parts. SINCE THE PIECE WORK PAYROLL SYSTEM IS ALWAYS UNDER DEVELOPMENT THERE MAY BE DIFFERENCES BETWEEN THE MANUAL AND THE ACTUAL PROGRAM. OBVIOUSLY, IT IS WISER TO FOLLOW THE PROGRAM SCREEN. IF THERE ARE MAJOR CHANGES, WE WILL ATTEMPT TO PROVIDE UPDATED MANUAL SECTIONS TO GUIDE THROUGH THE CHANGES. ACCESSING WWW.ASAPOFGA.COM AND FOLLOWING THE ‘MANUALS’ LINK CAN REQUEST CURRENT REVISIONS OF THE MANUALS. PLEASE REMEMBER TO UTILIZE THE <F1> HELP KEY WHEN WORKING IN THE PROGRAM. If the Piece Work System is integrated with other modules of the AS/AP™ Accounting System, there are three prerequisites to the proper operation of the Piece Work System. There must be an Active Cutting Order Number, a valid Style Number, and a Size Range. There are also two fields that must be completed in the Company Master File (Refer to the Utility Manual). One field is the Hourly Base Rate that the SAM's are to be expanded by. We provide your company with up to 7 different rate levels to use for different base rates. Most of our clients use Rate 1 for the federal minimum wage. On piecework, we check this field and do not pay below it. It could be used for whatever minimum pay level desired if your company’s operators are offered a higher level than the federal minimum. The remainder would be used for different skill levels. For example, one base rate may be paid for a sewing job, and a different base rate for a handling job. In System Flag 249 the default base rate, which is used when keying in a manual rate for an operator is set (see Enter Daily Gross Pay Data on page 56). The second field is the Next Piece Work Ticket Number. This is the next number assigned to and used for the piecework ticket printing. For a discussion of the required Employee data, please see the Gross-to-Net Payroll manual.

Rate Basis Since there are several system flags, which affect this area, it was necessary to make Rate Basis a section on its own. Rate Basis is the basis on which the operator’s base rate will be determined. In general, but, not always, the operator will be made up to this rate.

Work Codes/Off-Standard Codes In setting up the work codes and Off-Standard pay codes, the system uses three designations: M – Minimum: With the standard flag settings this will pay the rate that is entered in the Minimum field under selection <U-4-1-C-2>. B – Base: In AS/AP™ this refers to the rate of pay that is established in the employee file in field #7. If

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this is set to any other rate of pay that is what the employee will be made up to for both on-standard and off-standard categories. This acts as an employee’s personal minimum and will supersede ‘M’ as a rate of pay. A – Average: This will pay the six-week, thirteen week, or quarterly average. Enclosed are several examples of how the codes are normally applied. Excluded from these examples are any using ‘Averages’ since this normally does not create any problems. If there should be any questions regarding how a pay calculation is handled, or could be handled by the system, please send the necessary information. The base rate table for all the plants is found under selection <PY-A-0>. Enter the plant number to select which plant and then ‘E’ to edit each individual table.

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PIECEWORK TICKETS


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PIECE WORK TICKETS Upon selecting the option for Piece Work Tickets from the Main Payroll menu the user may receive a message pertaining to updating of files, mainly coupons. After this message, or in lieu of it, the user will receive the following submenu:

This section includes the functions required to create the Piece Work Tickets. The Operations and Rates are maintained in the Rate Book. The Operations are then assembled into the proper order through a Garment Breakdown. Each individual Style must have its' own breakdown which is used for both costing, and Piece Work purposes. The Bundle information is then entered, and the Piece Work Tickets can be numbered and then printed. After the Tickets are printed, the company can have either of two setups. Work normally goes into the Work Pool, before being placed into work. However, if System Flag 246 = "Y", the Work Pool is bypassed, and work is committed to WIP as soon as the tickets are printed.

Rate Book Maintenance This function is used to add, edit or delete entries from the Rate Book. The Rate Book simply contains a list of Operations, Descriptions and the SAMs (Standard Allowed Minutes - Decimal Minutes) assigned to the operation. The Rate Book, in essence, is a master list of all of the Operation Codes (Op Codes) that are in effect at the company. Selecting ‘1’ will display the following Rate Book screen (see Figure 1.1):

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Figure 1.1: Operation Rate Book

The user may first receive a prompt to select the company base rate to use (if ‘multiple companies’ is active). This sample screen illustrates how the Operation codes will be displayed, as well as the available options (at the bottom of Figure 1.1). To add a new Operation code select the ‘Add New’ button at the bottom of the screen (shown to the left). The following are the fields that will now be highlighted at the bottom of the screen. In the Code field enter up to a six-digit operation code number. The codes ‘Break’, ‘Ctrl’, ‘999’ and ‘Void’ are special operation codes that can also be entered. The user cannot change the code when editing a current rate, only when <Ins>erting a new rate. The user cannot edit the operation code itself. If a different code is needed, add it and delete the old one if it isn’t currently in use. The Rate Status can be one of 4 classifications. Unless, your system has special or custom flags set, all of the present Rate Status are used for notation only. The 4 classifications are: <A>ctive: This means that the rate is current and approved.

<E>stimate: This can be used to identify rates that are not fully studied.

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<H>eading: This is used for non-paid entries intended for formatting on printed lists. (Some Coupon Printing routines don't display this rate)

<T>emporary: This rate is generally used for costing, but is not intended for publication. (Some Coupon Printing routines don't display this rate) SOME SYSTEMS ARE SET TO NOT PRINT ESTIMATED RATES ON RATE TICKETS. THE SYSTEM ASSIGNS A DEFAULT STATUS OF <A> TO NEW RATES AS THEY ARE ENTERED. In the Description field enter the full operation description. This is the full (25 character) description of the operation. An optional System Flag permits this field to be expanded to 40 characters. The Ticket field is what will appear on the printed Piece Work Tickets. Enter up to an eight-character ticket description. Since there is not enough room on the ticket for the full description, this should be an abbreviated description. Like everything with AS/AP™ there are exceptions to the length of the Ticket Description. Modifications have been made that permit longer Ticket Descriptions. Of course this modification also requires a custom Piece Work Ticket layout, in order to fit the longer description. The Standard Allowed Minutes [SAM] field is the time allowed to produce a single unit of the product in this one operation. In other words, this is the time allowed to produce one unit of something. The SAM is calculated by taking the Normalized (Time Study) time plus a Personal Fatigue and Delay (PF&D) allowance plus a bundle allowance. In simple terms, if an operator is timed on the operation, the time should be 10-20% less than the SAM or something is out of balance. This is because the SAM includes from 15-25% allowance above the actual time, plus a bundle allowance. After entering the SAM, the rate level (1 - 7) for this Operation Code and SAM must be provided. This is what is entered in the Level field. The computer automatically calculates and displays both the Rate per Production Unit (based on the Base Rate in the Company Master File) and the number of times this operation can be performed in a 480 minute day, which is also known as the yield (In the Operation Rate Book display, this number is shown under the column heading Day see Figure 1.1). The Personal Fatigue & Delay [PF&D] field is for providing an allowance for personal time, delays, and fatigue (as normally encountered in a standard work day). The PF&D usually begins at 15% and can range to 20 or even 25%. The Machine/Group field is simply machine, machine grouping, or operator grouping. THIS IS NOT AN AREA TO TAKE LIGHTLY. IT'S EASY TO INSTALL A RATE, AND EVEN EASIER TO INSTALL A BAD RATE. THE RATE'S THAT ARE IN THE COMPANY'S FAVOR WILL BE EASY TO REVISE, THE MISTAKES IN THE OPERATORS FAVOR, HOWEVER, ARE NEARLY IMPOSSIBLE TO CHANGE. GET REAL LIVE HELP BEFORE IT'S TOO LATE! THE BIGGER THE MISTAKES AND THE LONGER THE BAD RATES ARE IN EFFECT, THE HARDER THEY ARE TO CORRECT. To edit an Operation code, simply highlight the desired code to edit and click on the edit button at the bottom of the screen (shown to the left). Once complete, press the Save button (shown to the left) to complete the process of adding or editing an Op code.

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If the changes made are not desired or the user wishes to stop the process of adding a new operation code simply press the ‘Undo’ button (shown to the left) at any time to return to the viewing screen (Figure 1.1). To delete an existing operation select the Operation code that you would like to be deleted and click the delete button in the toolbar (shown to the left). The operation code and description will be displayed, along with a prompt similar to the one shown below.

A <N>o will return to the Rate Book screen. A <Y>es will delete the code and redisplay the Rate Book screen in the proper order without the deleted code. IF AN OPERATION, WHICH IS CURRENTLY IN USE, IS DELETED IN A GARMENT BREAKDOWN, UNPREDICTABLE RESULTS COULD BE EXPERIENCED, INCLUDING LOSS OF DATA! FOR THIS REASON, WE DO NOT RECOMMEND THAT AN OPERATION IS DELETED UNLESS ABSOLUTELY SURE IT IS NOT IN USE AT ALL. PLEASE BE CAREFUL! When completed making additions, deletions, or changes to the Rate Book file click the ‘Exit’ button (shown to the left) and the user will be returned to the Piece Work Tickets submenu.

Garment Breakdown Maintenance This function is used to add, edit or delete entries from the Garment Breakdown file. The Garment Breakdown lists the operations necessary to produce a specific style. TICKET SEQUENCE HAS NO DIRECT RELATIONSHIP TO SCANNING SEQUENCE IN THE COMPUTER; HOWEVER, THE TICKET SEQUENCE IS IMPORTANT FOR TRACKING PURPOSES IN GENERAL. A WELL DESIGNED AND THOUGHTOUT SEQUENCE WILL IMPROVE VISIBILITY OF PRODUCTION FLOW. COUPONS SHOULD FOLLOW A LOGICAL SEQUENCE. THE SEQUENCE IS USUALLY BASED ON THE SEQUENCE IN, WHICH THE COUPONS ARE REMOVED FROM THE SPINE. THE 999 COUPON WILL END THE PROCESS. BUT, THE 999 TICKET CAN APPEAR ANYWHERE IN THE SEQUENCE. GENERALLY THE USER WOULD DESIGN THE TICKETS SO THAT THE 999 COUPON IS LEFT ON THE SPINE AFTER ALL OF THE OTHER COUPONS ARE USED. When the user selects option ‘2’, they will receive the following submenu (if multiple companies are active the user may receive a prompt concerning selection of the company base rate to use):

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Maintain Garment Breakdowns When option ‘1’ is selected, the user will receive the following screen:

Figure 1.2: Garment Breakdown

Enter up to a 12-character style number. This must be a valid Style, known to the System. In other

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words, the Style must be entered through Style Maintenance before selecting this option. Enter a warehouse designation if applicable. Press <Tab> or <Enter> to propagate the table and fields on the screen. To add an operation code to the breakdown or edit an existing operation code click on the ‘Add New’ or ‘Edit’ button from the Line Sequence Maintenance box (shown below) in the bottom-right hand corner of the screen.

If your system has system flag 475 turned on, the user will see fields for Alt1 and Alt2, once an operation code is selected. For a complete discussion on this, please see Appendix B - Alternate Operation on page 100 of this manual. Make any necessary corrections to the Code and Description, and to the Alternates, if applicable. Press ‘Save’ button (see Line Sequence Maintenance box above) to save the changes made to the line. To change a rate, simply return to the 'Rate Book Maintenance' option and edit the desired operation, which in turn, is reflected in all breakdowns using that same Operation Code. When complete inserting lines, pressing ‘Save’ will redisplay the Garment Breakdown screen in the new order specified. CHANGING A RATE (SAM) IMMEDIATELY EFFECTS ALL PIECE WORK TICKETS WHETHER OR NOT THEY HAVE BEEN PLACED INTO WORK AS LONG AS THEY HAVE NOT BEEN SCANNED FOR PAYROLL PURPOSES. If the tickets have been scanned during the current Piece Work Week, but, the user still wants the rate change to be effective, they can use the Payroll Menu Option: Reset/Delete Payroll Data. This Option has the effect of unscanning a days worth of tickets for the selected operator. They can then rescan the tickets and the new rate will automatically be used for calculating the earnings. To delete an existing operation, select the line you would like to be deleted and click ‘Delete’ button (shown above in Line Sequence Maintenance box). The operation code and description will be displayed, along with the following prompt:

A <N>o will return to the Garment Breakdown screen. A <Y>es will delete the code and redisplay the Garment Breakdown screen in the proper order without the deleted code. IF AN OPERATION IS DELETED WHICH IS CURRENTLY IN USE IN A GARMENT BREAKDOWN,

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UNPREDICTABLE RESULTS COULD BE EXPERIENCED, INCLUDING LOSS OF DATA! FOR THIS REASON, WE DO NOT RECOMMEND DELETING AN OPERATION UNLESS ABSOLUTELY SURE IT IS NOT IN USE AT ALL. PLEASE BE CAREFUL! If there is any time during the adding or editing process that the user wishes to reverse what has been done to the overall Breakdown, pressing the ‘Undo’ button from the Working File Maintenance box in the bottom-right hand corner (shown below) will revert to the previously saved version.

Once completed making additions, deletions, or changes to a specific style, pressing the ‘Save’ button for the Working File (see Working File Maintenance box above) will save the file so that changes can be seen on the screen. To complete the process and update the file click the ‘Save’ button in the upper-right hand corner and then press the ‘Exit’ button to close the form and return to the Garment Breakdown Maintenance submenu. Basically, it is a 5-step process for adding/editing/deleting codes from the garment breakdown:

1. Enter Style/Warehouse and hit <Tab> 2. Click ‘Add’ button and select Before or After current record 3. Enter the necessary information and press ‘Save Line’ 4. Press ‘Save Working File’ 5. Press ‘Save Garment Breakdown’ (top right corner)

There are a number of important items to remember and steps 4 & 5 above can be done at the end, they do not need to be done during the process. By saving all along you will be able to see the progress and ensure the updating is going as planned. IF THERE IS AN ODD NUMBER OF OPERATIONS LISTED IN THE GARMENT BREAKDOWN, A VOID TICKET WILL BE AUTOMATICALLY INSERTED TO PROVIDE AN EVEN NUMBER OF TICKETS THAT PRINT. THE BREAK OPERATION CODE IS USED TO CREATE A SEPARATION BETWEEN OPERATIONS, AND WILL LIKEWISE INSERT A VOID TICKET IF THERE IS AN ODD NUMBER OF OPERATIONS LISTED. VOID TICKETS THAT ARE GENERATED IN THIS MANNER WILL NOT BE ACCESSIBLE TO THE SYSTEM IF NEEDED AT A LATER TIME. IT IS RECOMMENDED THAT THE VOID TICKET BE LISTED IN THE GARMENT BREAKDOWN TO PROVIDE AN EVEN NUMBER OF OPERATIONS FOR PRINTING. BY LISTING A VOID IN THE BREAKDOWN THE TICKET WILL BE ACCESSIBLE TO BE USED BY THE PROGRAM AT A LATER TIME. WHEN USING A VOID TICKET TO REPLACE A LOST TICKET, OR WHEN AN EXTRA OPERATION HAS BEEN ADDED, A LISTED VOID CAN BE CHANGED AND THEN SCANNED INTO THE SYSTEM. AN AUTOMATICALLY CREATED VOID TICKET WILL NOT HAVE THIS CAPABILITY. If a style number, which is not known to the system, is entered, the user will receive the following prompt:

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Responding <N>o will return to the ‘Enter Style’ prompt. A <Y>es will further prompt:

A <Y>es will prompt the following:

When a valid style number has been entered the Garment Breakdown screen will appear with the information from the copied style, but the style number, at the top, will now be the new one (see Figure 1.2 for the Garment Breakdown screen). Selecting <N>o when prompted if the user would like to copy from an existing breakdown will return the customer to the Garment Breakdown screen. The user then continues entering operation codes until the new style breakdown is complete. Exit the screen will prompt as to if the user wishes to ‘Update the Master File.’ To save this new style select <Y>es otherwise select <N>o to return to the Style prompt ignoring the new entry. Once complete pressing <Esc> from the Style prompt will return the user to the Garment Breakdown Maintenance submenu.

List Styles with Common Operation When the user selects option ‘2’ on the Garment Breakdown Maintenance submenu they will first be prompted:

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Enter Operation Code(s) Below (Blank when finished)… ___________ ___________ ___________ ___________

After leaving a field blank and pressing <Enter> they will further be prompted:

Selecting <C>ancel returns to the Garment Breakdown Maintenance submenu. A <N>o will return to the 'Enter Operation Code(s)...' prompt to continue entering codes. Responding <Y>es will further prompt:

Selecting rinter will prompt the Windows Printer Dialog box. When the printing is complete the user will be returned to the Garment Breakdown Maintenance submenu. Selecting <S>creen, on the other hand, will display the following Style List screen (see Figure 1.3):

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Figure 1.3: List of Common Operation Codes

Once complete, pressing <Esc> will return to the Garment Breakdown Maintenance submenu.

Insert Operation in Multiple Styles THIS OPTION IS AVAILABLE BY SPECIAL ORDER. CONTACT YOUR SOFTWARE VENDOR FOR ADDITIONAL INFORMATION CONCERNING THIS AREA.

Change Operation in Multiple Styles When the user selects ‘4’ from the Garment Breakdown Maintenance submenu their first prompt will be:

Change From Which Operation Code (<Esc> to Quit)? __________ Pressing <Esc> will return to the Garment Breakdown Maintenance Screen. If a code is not found the user will be informed of such and returned to the previous prompt. Once a valid code has been entered the user will receive the following prompt:

Change To Which Operation Code (<Esc> to Quit)? __________ Once a second valid code has been entered the following prompt will appear:

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A <N>o will return to the first prompt for reentry. A <Y>es, on the other hand, will further prompt for the user to enter any necessary styles. Once complete the user will be prompted as to if they have completed entering styles. Responding <N>o allows the user to continue entering styles. A <Y>es will further prompt if it’s ok to process the changes now. A <N>o will return to the first prompt, while a <Y>es completes the changes and then returns to the first prompt. Once complete, pressing <Esc> will return to the Garment Breakdown Maintenance submenu.

Delete Operation in Multiple Styles THIS OPTION IS AVAILABLE BY SPECIAL ORDER. CONTACT YOUR SOFTWARE VENDOR FOR ADDITIONAL INFORMATION CONCERNING THIS AREA.

Delete Obsolete Breakdowns The first prompt the user will receive once they have selected ‘6’ from the Garment Breakdown Maintenance submenu is:

Once entering a valid style, the following prompt will appear:

Selecting <Y>es, that the system is to verify the Breakdown's current use, will, for example, prompt that the style is in the work pool and prompts the user as to if they wish to delete it. If the user selects <N>o, they will be returned to the 'Enter Style' prompt. A <N>o to the verification prompt, or a <Y>es to the previous prompt will further prompt for the user to confirm that they do indeed want to delete this style. If the user selects <Y>es they are prompted that the system is packing and reindexing, when finished they will be returned to the Garment Breakdown Maintenance submenu. If <N>o then the user is returned to the 'Enter Style' prompt.

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Pack and Reindex Breakdown File The first prompt that the user will receive, upon selecting option ‘7’ is:

A <N>o will return to the Garment Breakdown Maintenance submenu. A <Y>es will first pack and reindex and then return to the submenu. Pack and Reindex is a function that completes the deletion (permanent removal) of records from a database file and reduces the file size. Depending on which file and indexes are involved this function can cause some delays and should usually be performed at the End of Day if the option to do so is offered.

Update Style Master File Costs Upon selecting option ‘8’ the following prompt will appear:

A <N>o will return to the Garment Breakdown Maintenance submenu. A <Y>es, on the other hand, will display the following message on the screen:

Updating Style File Costs… Once complete, the user will be returned to the submenu along with an ‘Update Complete’ message.

Update Raw Material Master THIS OPTION IS AVAILABLE BY SPECIAL ORDER. CONTACT YOUR SOFTWARE VENDOR FOR ADDITIONAL INFORMATION CONCERNING THIS AREA.

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Material Code Table THIS OPTION IS AVAILABLE BY SPECIAL ORDER. CONTACT YOUR SOFTWARE VENDOR FOR ADDITIONAL INFORMATION CONCERNING THIS AREA.

Bundle Sheet Data This function, ‘3’ from PW Tickets menu is used to provide an image of the actual cutting order. The bundle sheet is actually a 2 dimensional array, but don't let that scare you. It is undoubtedly the most difficult part of the system for some people to understand. Below is a sample of a handwritten bundle sheet for a particular Lot cut in a 2-6-4 Ratio in Red, White, and Blue:

Patterns/Sizes Sml Med Med Med Lrg Lrg Total Ply Clr 12 RED 12 12 12 12 12 12 72 6 WHT 6 6 6 6 6 6 36 6 BLU 6 6 6 6 6 6 36 12 BLU 12 12 12 12 12 12 72 === === === === === === === Totals 36 36 36 36 36 36 216

The garment in this example is available in 3 sizes (Small, Medium, and Large). The following is a profile of the sample cutting (shown above):

216 pieces 36 pcs Small 108 pcs Medium 72 pcs Large 216 pieces 72 pcs RED 36 pcs WHT 108 pcs BLU 24 bundles 4 bdl Small 12 bdl Medium 8 bdl Large

If the information to this point is not understood, it may not be wise to continue. This is a basic principle of spreading, cutting and markers which we are describing as simply as possible. Besides, what we refer to as the Bulk Bundle Ticket entry will probably be more appropriate for your company’s situation. The first prompt the user received may be the following:

Selecting either response will prompt for the ‘CO/WO Number.’ The system will then continue as if one

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of the selections below had been made. The first prompt may be the following:

Selecting <A>utomatic will first prompt the following:

Enter the Cutting Order/Lot number and the bundle tickets will be automatically created. The bundles will be broken down according to a set of predetermined rules. In other words, in the style file the user enters the standard bundle count for each body style. Once complete the user will be returned to the Piece Work Tickets submenu. Selecting ulk from the above prompt will again display the ‘CO/WO’ prompt. Once a valid CO/WO number has been entered the following line will be displayed:

CO 000109 Lot Style ____________ Clr ___ Dim ___ Whs 000 Entering the appropriate style, color, dimension will display the following prompt:

The following screen will then appear:

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This option allows the user to enter the number of bundles by style, size, color, and dimension of a specific quantity. For example, there are 10 bundles with 24 pieces each of Red, size Small. The Pieces per Bundle and Total Pieces are also to be entered. After entering the bundles, pieces per bundle, and total pieces the user will receive a size chart for selection of the size. After selecting a valid size for the quantities entered the user will receive the following prompt:

If the style/color/dimension needs to be changed select <C>ancel to return to the ‘Style’ prompt. Selecting <N>o will allow the user to change the bundles/pieces information. To continue, accept the numbers entered, and create the record select <Y>es. The record will then be created and the user will be returned to the bundles/pieces line. Once complete pressing <Esc> will prompt the following:

To save the bundles just created select <Y>es otherwise select <N>o to disregard anything just entered. The user will then be returned to the ‘Style’ prompt. Once complete pressing <Esc> will return the user to the ‘CO/WO’ number prompt and <Esc> again will return the user to the Piece Work Tickets submenu. Selecting <S>pread from the initial prompt will again prompt for a CO/WO number. Once a valid cutting order number has been entered the system will display the Style and Range for the cutting order so that the user can confirm (press <Enter>) or deny (press <Esc>) that it is the correct one. Assuming it is the correct one the following screen will appear (see Figure 1.4):

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Figure 1.4: Spread Bundle Sheet This option ‘Spread’ is the most cumbersome and requires the user to identify each individual bundle. Accept the sequence number displayed by pressing <Enter> or enter a new sequence number. Then enter a color and dimension code, followed by the ply of the bundle. Next the user will be presented with the bundle array. This is where the user enters the number of the size range for each piece, as specified on the cutting order. In the example above, the bundle array would be for 3 of size one (Small), 3 of size two (Medium) and 3 of size three (Large). To add a line to the bundle sheet above press <Ins>ert and select whether the line is to appear before or after the existing line. This allows the user to insert a new bundle sheet line before or after the line they’re currently on. As the user enters new lines, the system uses the previously entered data as a default. Therefore, the operator just changes the portion of the data that changes on each subsequent line. If several duplicate lines are entered, the operator can just keep repeating the data by pressing <Enter>. To edit an existing Bundle Sheet line, use the up or down arrows to 'point' to the sequence line number and press <Enter>. The sequence, color, ply, and bundle array information will be displayed. After making any necessary changes, the Bundle Sheet screen will be redisplayed with the new information. Deleting a line can be done by simply highlighting the line and pressing <Del>ete. The user will then confirm deletion of the line. Once complete pressing <Esc> will prompt as to if the user wishes to update the master file with the new information. The Piece Work Tickets submenu will then be redisplayed.

Assign Numbers and Print Tickets This function merges the Rate Book, the Garment Breakdown, the Bundle Sheet information and Number assigned in the previous function and ties them together to form the Piece Work Ticket. Any error or inconsistency in the data fed to the ticket-printing program will print at this point. It is extremely important to Check All Data before taking this option. Once tickets are printed, it is very awkward to explain to the operators that the information on the ticket is wrong, but, they will be paid

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correctly. It is a lot easier to get it right the first time by checking the data carefully before printing the tickets. The user must have the correct printer selected before entering this function. We have found that an effective setup is to designate the ticket printing function to one workstation which has it's own local printer hooked to it. We do not recommend using a network printer for this function! In fact, we strongly discourage using a networked printer for printing tickets! We further recommend that the user always use the same login name for printing the tickets, then set up the printer as that user's default (please refer to the “Security Section” in the System Utility manual for instructions on this). They will still be asked to pick a printer when it comes time for the actual ticket printing, but they may notice that the correct printer has been preselected. There are 20 label configurations available to users. The Standard and least expensive ticket used by the Piece Work Ticket System is 2 1/2" X 15/16" - 3 across (Mailing Labels). The most professional ticket layout is 2 1/2" X 3/4" - 3 across. However, this stock is NOT a Standard Label, and must be purchased direct from the manufacturer or through your dealer. These labels are color coded and made of heavy weight stock. IF YOU ARE RUNNING THIS OPTION, MAKE SURE THAT YOUR PRINTER IS SET WITH CURRENT FORM LENGTH. When the user selects ‘4’, the first prompt will be:

Upon entering a valid cutting order/lot number combination, they will receive the following message:

Assigning Ticket Numbers…

Updating Work Pool… When the system is finished assigning the ticket numbers and updating the work pool the user will receive the following prompt:

If the user chooses NOT to print at this time, they can always go back and utilize the reprint functions, see option ‘5’ from the Piece Work Tickets submenu (page 32). Choosing <N>o will return to the Piece Work Tickets submenu. Selecting <Y>es, however, will further prompt the Windows Printer Dialog box. Once the printing is complete the user will be returned to the

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Piece Work Tickets submenu.

Reprint PW Tickets This function allows for the reprinting of tickets that have already been printed, for those times when the printer jams on the initial run of the tickets, or runs out of ribbon, etc. This option can also be utilized when the user opted to not print the tickets in the previous option ‘4’, Assign Numbers & Print Tickets (page 30). IF YOU ARE RUNNING THIS OPTION, MAKE SURE THAT YOUR PRINTER IS SET WITH CURRENT FORM LENGTH. When the user selects option ‘5’, the first prompt will be:

Cutting Order Number to Print? __________ Lot Number __________ <F7> to Lookup - <Esc> to Quit

Upon entering a valid cutting order/lot number combination, the user will receive a message stating that the tickets for the above cutting order/lot combination have already been printed. The reprint tickets module is password protected. As the program is distributed, the password is MASTER. To continue, enter the password followed by <Enter>. The password will not show on the screen, so type carefully. Also, be sure to type the letters in uppercase only to match the password exactly! The password 'master' does not match the password 'MASTER'. Provided the user entered the password correctly, they will receive the following message and prompt:

These tickets cover the following number range

Enter the desired starting point below

Start at: 900064 Finish at: 900083 The default numbers for the range are based on the entire cutting order/lot combination entered to be reprinted. The user can change the 'Start At' field, but not the 'Finish At' field. To reprint the entire cutting order, simply press <Enter> to accept the default range. After selecting the ticket to begin printing, the user will receive the Windows Printer Dialog box. If the tickets come out with strange spacing, the user will have to reset the printer and print them again. We suggest they take the following steps:

1. Turn off the power to the printer, and then back on again after 2 or 3 seconds. 2. Select the "Reprint Piece Work Tickets" option and enter the Cut/Lot to reprint. 3. Take at least one ticket alignment sequence. 4. Allow the cut to print.

In most instances, this solves the problem. Once complete the user will be returned to the Piece Work Tickets submenu.

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Place Cut Into Work This option is used to place the cutting orders that are in the Work Pool into the Work-In-Process. When the user selects ‘6’, the first prompt will be:

Cutting Order Number: __________ Lot Number: __________ Upon entering a valid cutting order/lot number combination, the user will receive the following prompt:

A <N>o will return to the 'Cutting Order Number' prompt. A <Y>es will prompt for the user to wait a few seconds while marking the data for the move and then return to the 'Cutting Order Number' prompt. Think About This: The Work Pool is an Option that can easily be bypassed. Not every company can use it effectively. In addition, the Cut Work Pool adds another step to the process because Goods that go into the Pool must eventually be placed in Work-in-Process. The advantage of placing Cut Work into the Work Pool is that the WIP reports are kept pure and only reflect work that is committed to the sewing floor. If your company does NOT need the Work Pool, ask the dealer to change the Flag setting of your company’s system.

PW Ticket Reports This function allows the user to print various piecework payroll reports. When they select ‘7’, the following submenu will appear:

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Rate Book (Operations) This selection prints a report of the Rate Book information by Operation Code. Included are the Operation Code, Ticket Description, Full Description, SAM, Expanded Rate and the Number of Pieces Per Hour and Per Day. When the user selects ‘1’, they will first be prompted:

Show only <E>stimated, <T>emporary, or <A>ctive Rates. Leave Blank to List all Rates _

Regardless of which rate is chosen the following prompt will appear:

Responding <N>o will jump to the ‘Do you want to list the operational detail prompt’ below. Selecting <Y>es will prompt the following:

Enter Lowest Operational Code ____________

Enter Highest Operational Code ____________

The following prompt will then appear:

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Selecting <N>o will allow the user to reenter the lowest and highest operational codes. Once <Y>es has been selected the following prompt will appear:

Either response will prompt the following:

Then the 'List of Piece Rate Codes' is either displayed on the screen or the user will receive the standard printer report control prompt. Once complete the user will be returned to the Piece Work System Reports submenu.

Garment Breakdown This selection prints a report of the Garment Breakdown information by Style Number. Included are the Sequence Number, Operation Code, Ticket Description, Full Description, SAM, and Expanded Rate. Each style is listed on a separate page. Once option ‘2’ is selected, the first prompt will be:

The user can press <Enter> to select this report for all styles, or enter the single style number they want the report for.

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If the Labor Evaluation is active on the system, the user will be prompted to include the summary. This will add cost and markup information to the end of the Breakdown. The user will then be prompted:

Then 'Garment Breakdowns' are either displayed on the screen or printed. When finished, they will be returned to the Piece Work System Reports submenu.

Bundle Sheet (Tickets) This selection prints a report of the Bundle Sheet information per Cutting Order Number. Included are the Sequence Number, Ply, Color, Available Sizes (listed with their description) and the Total Pieces. If this report is run after the tickets have been printed, the Ticket Number will also appear on the report. When selection ‘3’ is made, the first prompt will be:

Upon entering a valid cutting order/lot number combination, the user will receive the Windows Printer Dialog box. When the report is finished, they will be returned to the Piece Work System Reports submenu.

Bundle Check Off List This selection prints a report of the Bundle Sheet Ticket information per Cutting Order Number to be used as a check-off list. Included are the Sequence Number, Ticket Number, Size, Color Code, Color Description, Quantity and two columns for 'IN' and 'OUT'. If this report is run after the tickets have been printed, the Ticket Number will also appear on the report. When the user selects ‘4’, the first prompt will be:

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Upon entering a valid cutting order/lot number combination, the user will receive the Windows Printer Dialog box. When the report is finished, they will be returned to the Piece Work System Reports submenu.

Work-in-Process by Style This selection prints a report of the Work-In-Process by Style Number. Included are the Style Number, Operation Code, Full Description, Bundles, Pieces, SAH, and Value. Upon selecting option ‘5’, the following prompt will appear:

The user can press <Enter> to select this report for all styles, or enter the single style number they want the report for. Next they will be prompted:

The W.I.P. list by Style will then either be printed or displayed on the screen. When finished, the user will be returned to the Piece Work System Reports submenu.

Work-in-Process by Cut/Lot This selection prints a report of the Work-In-Process by Cutting Order/Lot Number. Included are the Cutting Order/Lot Number, Operation Code, Full Description, Bundles, Pieces, SAH, and Value. The first prompt that will appear, once option ‘6’ is selected is the following:

Cutting Order Number (<CR> for All, <Esc> to Quit) __________

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Lot Number __________ The user can simply press <Enter> to select this report for all cutting order/lot number combinations, or enter the single cutting order/lot number desired for the report. Next they will be prompted:

Regardless of whether the user responded <Y>es or <N>o to the previous prompt the following prompt will appear:

The W.I.P. list sorted by Cut/Lot will then either print or be displayed on the screen. Once complete, the user will be returned to the Piece Work System Reports submenu.

Work-in-Process by Operation This selection prints a report of the Work-In-Process by Operation Code. Included are the Operation Code, Full Description, Bundles, Pieces, SAH, and Value. After selecting option ‘7’ the following prompt will appear:

Operation Code (<CR> for All, <Esc> to Quit) __________ Again, the user can elect to print this report for all operation codes by pressing <Enter> for All, or enter the single operation code desired. The following prompt will then appear:

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The W.I.P. list by Operation will then either be printed or displayed on the screen. When finished, the user will be returned to the Piece Work System Reports submenu.

Work-in-Process Summary Once selecting option ‘8’ the following prompt will appear:

Once a valid cutting order number has been entered, or the field has been left <Blank> for all cutting orders, the user will receive the Windows Printer Dialog box. Once the summary has completed printing the user will be returned to the Piece Work System Reports submenu.

Graphic – WIP by Cut/Lot This option prints a report listing the Cutting Order/Lot number selected along with the tickets assigned based on the color/size/quantity information. The first prompt that the user will receive upon selecting option ‘9’ from the Piece Work System Reports submenu is:

After entering a valid cutting order number the user will receive the standard printer report control prompt. Once complete they will be returned to the submenu.

Work Pool by Style This selection prints a report of the Work Pool by Style Number. It will look almost exactly like the Work-In-Process by Style Number report above. When the user selects ‘0’, they will receive the same prompts as shown in selection ‘5’ – Work-in-Process

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by Style on page 37.

Work Pool by Cut/Lot This selection prints a report of the Work Pool by Cutting Order/Lot Number. It will print exactly like the Work-In-Process by Cutting Order/Lot Number report above. When the user selects ‘A’, they will receive the same prompts as shown in selection ‘6’ – Work-in-Process by Cut/Lot on page 37.

Work Pool by Operation This selection prints a report of the Work Pool by Operation Code. It will print exactly like the Work-In-Process by Operation Code report above. When the user selects option ‘B’, they will receive the same prompts as shown in selection ‘7’ - Work-in-Process by Operation on page 38.

Work Pool Summary The Work Pool Summary provides the user with all of the cuts along with their applicable styles, dates, and amounts cut. The first prompt the user will receive, upon selecting option ‘C’ is the following:

The Windows Printer Dialog box will then be displayed. Once the printing is complete the user will be returned to the Piece Work System Reports submenu.

Operation Code Performance THIS OPTION IS AVAILABLE BY SPECIAL ORDER. CONTACT YOUR SOFTWARE VENDOR FOR ADDITIONAL INFORMATION CONCERNING THIS AREA.

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WIP Labor Valuation This selection, ‘W’, creates a report which tells how much labor has already been paid to any Work-in-Process. This is very useful at the close of a period, as it allows your company to assign an actual and realistic dollar amount to the garments, which are still in production. For convenience, this report can be taken to either the Screen, or to the Printer. The $ value is summarized by cut/lot number. On the screen, it keeps a running total in the right hand column. On the printed copy, the total is placed at the end of the report. This report may show cuts which are no longer in Work-In-Process. The reason for this is due to the contents of the Piece Work Open Tickets file. When the user scans or keys in a '999' ticket, the bundle is marked as complete. However, the bundle record still exists in the file. The records MUST stay in the file until all of the operators who have worked on that bundle are paid (usually within one or two days). After that, the bundle record can be deleted. This is performed automatically when the user processes the Gross to Net payroll (see page 76). This report may also show bundles, which have been canceled. The function to cancel a bundle also leaves the bundle records physically in the file. Therefore, it is a good idea to purge and pack your piecework files on a regular basis. For a description of this function, please see page 88, Purge Cancelled Tickets. The first prompt that the user will receive is:

Then the report will either be displayed on the screen or the user will receive the Windows Printer Dialog box. Once complete the user will be returned to the Piece Work System Reports submenu.

Bundle Maintenance Functions This function allows the user to adjust bundle information. Upon selecting ‘8’, they will receive the following submenu:

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Delete Completed/Unused Tickets This function is used to remove completed tickets from the Open Item (AAPWOPEN.dbf) file. Normally, coupons are automatically deleted from the Open Ticket file when they are scanned and archived in the history file. When the '999' ticket is scanned into the Inventory Control section, the work is added to the Finished Goods Inventory and the unpaid tickets (coupons) are canceled. This function is ONLY needed if one of the normal methods of canceling tickets didn't work or was bypassed for some reason. When the user selects ‘1’, the first prompt will be:

Upon entering a valid cutting order/lot number combination, they will be prompted:

A <N>o will return to the 'Cutting Order' prompt. A <Y>es prompts the user to wait while the system is marking the record for deletion and returns to the 'Cutting Order' prompt. When finished marking records for deletion, press <Esc> at the 'Cutting Order' prompt. If any records were marked for deletion, the user will receive a prompt asking if they wish to update the master file. A <N>o at this point will reset all the records marked for deletion and return to the Bundle Ticket Main-

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tenance submenu. A <Y>es will display an 'Update in Progress' message on the screen, then return to the Bundle Ticket Options submenu.

Adjust Bundle Count This function is used to manually adjust the bundle counts. As the title implies, this function allows the operator to change the quantity in the bundle. This change will NOT affect ticket earnings already calculated. If the user wants to effect previous earnings, they will want to unscan the tickets BEFORE ADJUSTING THE COUNT. After selecting option ‘2’ the following prompt will appear:

Bundle Ticket # ______

Operation Sequence # ___

<Esc> to Quit The user must enter a valid bundle ticket/operation sequence number combination. THE CHANGE IN THE BUNDLE COUNT (QUANTITY) IS NOT PRESENTLY REFLECTED IN THE BUNDLE TICKET SHEETS. However, this may be modified at any time. There are technical restrictions that make it difficult, if not impossible to report such a change on the Bundle Sheet.

Change Operation on Ticket This is another maintenance function that is occasionally necessary. The operator is allowed to change a particular Operation Code to another Code although the tickets are already printed and even in work. This function can be used to Void an operation for an entire cut. The first prompt when the user selects ‘3’ from the Bundle Ticket Options submenu is:

Selecting <Y>es or <N>o will prompt for the following information:

Cut Number ______ Lot Number ______

Sequence Number ___ New Operation Code ______

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<Esc> to Quit

The user may press <Esc> to quit and return to the previous menu, at which point they will get one more chance to back out, Are you sure? Once complete the following prompt will appear:

If the Tickets are in the Cut Work Pool (not in production) they will be changed and the user will be given an opportunity to change another Operation Code. When completed they will be returned to the Bundle Ticket Options submenu. If the tickets are in the WIP file, the process will take a little longer. The first time a change is requested, the computer creates an index. After this delay, the computer proceeds to change the Operation Code. If a second change is requested, there is no delay for indexing because the index from the first change is used again. If the user wishes to Void an operation, they must first make sure that the Rate Book contains an operation named VOID and that it has a SAM value of 0.00 minutes. Then entering VOID at the point the system prompts for a New Operation Code. IF THE USER LATER TRIES TO SCAN A TICKET WHICH HAS BEEN CHANGED TO VOID, THEN THEY WILL BE INFORMED THAT A VOID TICKET CANNOT BE SCANNED. Why would anyone want to change a ticket to VOID? Suppose that there were 2 or 3 different ways to do a particular operation (for example: Set Pocket), and each different method paid a different rate. However, at the time of the cutting and bundling, the user doesn't know which method will actually be used due to changing loads out on the floor. However, when it comes time to actually perform the operation the user finds that the new Automated Pocket Setter is free. So by including all 3 ways in your bundle tickets, the user can VOID out the operations, which set the pocket by the old manual method, and just leave the operation for the new Automated Pocket Setter. This will: 1 - Prevent the incorrect tickets from being turned in and scanned by mistake and 2 - provide that the finished product shows the correct amount of labor which went into producing it. Once complete, pressing <Esc> will prompt:

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Selecting <N>o will return to the Bundle Ticket Options submenu. A <Y>es will prompt the standard printer report control prompt. Once the printing is complete the user will be returned to the submenu.

Scan Unpaid Tickets The first prompt that the user will receive after selecting option ‘4’ from the submenu is the following:

After entering a valid employee code the employee information will appear on the screen along with the 'Work Date' prompt, defaulting in with the current working date. Pressing <Esc> at this point will return to the 'Enter Employee Code' prompt. After entering a work date, or pressing <Enter> to select the default of the current date, the user will be prompted:

A <N>o will return to the 'Enter Employee Code' prompt. Selecting <Y>es, on the other hand, will further prompt:

SCAN TICKET <CR> to End or Manual Entry

At this point the user will either scan the ticket for the selected employee’s unpaid ticket(s) or press the <Enter> key to end the scanning process or to perform a manual entry of the ticket. Once complete the user will be returned to the 'Enter Employee Code' prompt. If finished, pressing <Esc> will return to the Bundle Ticket Options submenu.

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Void a Ticket When the user chooses this function, they are first presented with the following warning message:

Next they are presented with the entry screen to key a ticket (or tickets) to be Voided.

It is suggested that a bundle ticket be in front of the user when they try to VOID it. All of the information needed is contained on the ticket, and since all of the information MUST be correct and match, keying from the ticket insures that the correct information is entered.

Quality Control Adjustments The first prompt that the user will receive upon selecting option ‘6’ is:

Bundle Ticket # ___________ Operation Sequence # ___

<Esc> to Quit Once complete they will be returned to the Bundle Ticket Options submenu.

Change Inventory Status The first prompt after selecting option ‘7’ is the standard style code prompt. Once a valid style number has been entered the following prompt will be displayed:

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Selecting <Q>uit will return the user to the ‘Edit Style’ prompt. Select the appropriate option to change the style properties. Once complete, pressing <Esc> from ‘Enter Style’ prompt will return to the Bundle Ticket Options submenu.

Factory/Plant Assignment THIS OPTION IS AVAILABLE BY SPECIAL ORDER. CONTACT YOUR SOFTWARE VENDOR FOR ADDITIONAL INFORMATION CONCERNING THIS AREA.

Transfer CO to Factory THIS OPTION IS AVAILABLE BY SPECIAL ORDER. CONTACT YOUR SOFTWARE VENDOR FOR ADDITIONAL INFORMATION CONCERNING THIS AREA.

Import Exchange Data THIS OPTION IS AVAILABLE BY SPECIAL ORDER. CONTACT YOUR SOFTWARE VENDOR FOR ADDITIONAL INFORMATION CONCERNING THIS AREA.

Work-in-Process Scheduling After selecting option ‘9’ the following submenu will be displayed:

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There are steps that need to be followed at this point to ensure that the Work-In-Process Scheduling runs smoothly, so to speak. The first step that needs to be accomplished is to go into <PY-A-8-5> Machinery & Group Codes and set up the equipment codes and the projected number of operators available for each code. For further information on this topic please see page 93 of this manual. The next step is to go into <PY-8-1> Rate Book Maintenance on page 15 of this manual, and enter the machine codes into each rate in the Rate Book. Between these two steps the user now has the basic information that is required for each style breakdown. For the scheduling program, the first step is to set up the production/date break points. For this the user will want to go to <PY-8-9-5> Edit Production Schedule Dates on page 50. This step also requires an entry for the number of production hours that will be available for each week. After the dates are set, the next step is to input the actual projected production requirements using <PY-8-9-1> Enter Data to Schedule File, found on page 48 of this manual. The cut number and lot number can also be entered here, although it is not required. Finally, once the schedule is input, the next step is to calculate and print the results using <PY-8-9-6> Calculate and Print Schedule on page 51. This report will provide a projection of the number of SAH’s required, the Available Hours, and the variance for each Machine Code based on the scheduled input. There are also options that will allow the user to edit the schedule and then recalculate and print just the labor requirements.

Enter Data to Schedule File Upon selecting option ‘1’ the user will receive the standard ‘Style’ prompt. Once a valid style number has been entered the description will default in and the user will be prompted for the Color and after a valid code the Cutting Order, Lot number, and Date fields will open. After entering these, the size/quantity prompts will appear. Once the user has entered the quantity for the various sizes they will be prompted to add the data to the file. If everything is not correct take this chance to correct it. Both selections will return to the ‘Color Code’ prompt, however, responding <Y>es will write the data just entered to the file. When finished, pressing <Esc> will return to the ‘Style’ prompt and <Esc> again will prompt as to if the user wishes to update the master file. As with the previous prompt, both responses will return to the WIP

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Scheduling submenu, however, responding <Y>es will first update the Master file with the data that was just entered.

Edit Requirements/Schedule File Upon selecting option ‘2’ the following screen will appear (see Figure 1.9):

Figure 1.9: Edit Line Detail To edit a line, highlight it and press <Enter>. Make the necessary corrections and, after pressing <Enter> in the last field, the user will be returned to the Edit Line Detail screen with a message in the upper-right corner saying ‘Record Update Complete’. To delete a line, highlight it and press <Del>ete. The user will be prompted as to if they wish to proceed with the deletion. Both responses will return to the Edit Line Detail screen, however, responding <Y>es will delete the selected line. Once complete, pressing <Esc> will return to the WIP Scheduling submenu. After editing the line detail the user will either want to use option ‘6’ Calculate and Print Schedule Report (on page 51) or ‘L’ Recalculate Labor Requirement (on page 54) in order to ensure that everything is correct and calculated.

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List Requirements/Schedule File Upon selecting this option, ‘3’, the user will receive a message concerning printing the production schedule along with the Windows Printer Dialog box. An example of what will print is shown below (see Figure 1.10):

Figure 1.10: Production Requirements/Schedule Data

Reset Production Requirements If there is detail in the file, the first prompt that the user will receive upon selecting option ‘4’ gives the option of clearing it. A <N>o will return to the WIP Scheduling submenu. A <Y>es will clear the detail and reset the production requirements, then return to the WIP Scheduling submenu.

Edit Production Schedule Dates The first prompt that the user will receive upon selecting option ‘5’ concerns the number of days to increment the date table by. This ability to increment allows for the program to be a continuous operating tool, moving up one week at a time, as the schedule would normally progress. Once entering the number of days, or 0 (zero), and pressing <F10> to continue, the user will receive the start date and breakpoint prompts. After entering the last breakpoint the user will be prompted as to if

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they wish to record the new dates. Selecting <C>ancel will return to the WIP Scheduling submenu, ignoring anything just entered. A <N>o will return to the ‘Report Start Date’ field allowing for reentry of the breakpoints. And <Y>es will record the dates just entered and return to the WIP Scheduling submenu.

Calculate and Print Schedule Upon selecting option ‘6’ from the WIP Scheduling submenu, the user will be prompted as to if they wish to explode the labor requirements. Both responses will lead to a prompt concerning including the WIP, however, if the user selects <Y>es the Labor Requirements Report by Machine will print after the Production Schedule Report. Both responses to the ‘WIP prompt’ will then prompt the Windows Printer Dialog box. An example of what will print is shown below (see Figure 1.11):

Figure 1.11: Production Schedule Report

Print Production Schedule Only This option, ‘7’, will print the same as option ‘6’ above. The only exception is that this option will not prompt if the user wants to explode the labor requirements or include the WIP. This option gives the user only the printout of the production schedule.

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WIP Schedule and Labor The user will be begin this option with a prompt to explode the labor requirements. Either response will prompt if they wish to include the WIP. If the user responds <N>o to the WIP prompt, the following will be displayed (see Figure 1.11). If the user responds <Y>es, the following screen will be displayed (see Figure 1.12):

Figure 1.12: Requirements Report

Print Labor Requirements The first prompt that the user will receive after selecting option ‘0’ prompts if they wish to recalculate the labor requirements first. If the user selects <N>o they will immediately receive a prompt asking if they want the labor list by machine or operation code. However, if <Y>es is selected, they will receive a ‘Processing Labor Requirements’ message before receiving the prompt. If <O>peration Code is selected as the sorting mechanism a screen, similar to the following, will print (see Figure 1.13):

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Figure 1.13: Labor Requirements Report by Operation

If <M>achine was selected as the sorting mechanism the following is an example of what will print (see Figure 1.14):

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Figure 1.14: Labor Requirements Repost by Machine

Recalculate Labor Requirements The only message that will be displayed, upon selecting option ‘L’ is the following:

Processing Labor Requirements Once complete, the user will be returned to the WIP Scheduling submenu.

Rebuild Index Keys This function is intended to rebuild the index keys in the event that one or more become damaged. There is a selection on the Utility Menu that permits the operator to rebuild all of the indexes throughout the system. In addition, we have provided more specific reindex functions attached to most menu systems, like this option ‘I’, that are designed to index only the files required by that system.

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Cutting Incentive Maintenance THIS OPTION IS AVAILABLE BY SPECIAL ORDER. CONTACT YOUR SOFTWARE VENDOR FOR ADDITIONAL INFORMATION CONCERNING THIS AREA.

Bundle Ticket Options THIS OPTION IS AVAILABLE BY SPECIAL ORDER. CONTACT YOUR SOFTWARE VENDOR FOR ADDITIONAL INFORMATION CONCERNING THIS AREA.

Statistical Quality Control

THIS OPTION IS AVAILABLE BY SPECIAL ORDER. CONTACT YOUR SOFTWARE VENDOR FOR ADDITIONAL INFORMATION CONCERNING THIS AREA.

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PIECE WORK PAYROLL This selection controls the collection of Piece Work earnings to create the Gross Pay. Upon selecting the option for Piece Work Payroll from the Main Payroll menu, the user will receive the following submenu:

Enter Daily Gross Pay Data The first prompt that appears when the user selects ‘1’ from the Piece Work Payroll menu is:

To begin, the user enters in an operator's ID number. Next they enter the work date they are keying in. Enter the Regular hours worked for the day. The user is then presented with the default minimum rate (contained in her master file record) and her current Average. These can be overridden for this day's piecework. Overtime hours are next, and the premium portion, which at this point is figured at 1/2 of her minimum rate. Finally, we have a category labeled 'Other Pay' which allows the user to add a block of dollars to her daily pay (perhaps to make up for a previous shortfall in her pay). This is a hold over from our older system, and we find this option is rarely used.

Overtime Premium A flag setting is available for the calculation of the overtime premium for piecework employees. This flag setting is Flag 278 = G. This will calculate the overtime premium based on the following computation: TOTAL GROSS PAY DIVIDED BY TOTAL HOURS x 50% x O.T. HOURS The Gross Pay will include all compensation paid for off-standard, shift differential, subsidy (flag),

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makeup, training allowance (flag), holiday, vacation, and sick pay, in addition to the earned pay. The Total Hours will also include those hours attributable to Holiday, Vacation, and Sick hours. These hours are also used in calculating the overtime hours. To the best of our knowledge, this flag setting provides a calculation for overtime premium that is in compliance with the general accepted interpretation of Title 29, Part 778.111 of the Federal Regulations pertaining to Overtime Compensation under the Fair Labor Standards Act of 1938, as amended. This flag setting should be changed at the start of the pay cycle to ensure proper calculation for the entire continuous pay cycle. The system is designed for the overtime rate of the entire week to be recalculated when the overtime test is run at the end of the week. The weekly overtime premium verification program assumes 40 hours as the standard week and uses flag 603 to determine the number of hours in the standard day (1 = 10 hours per day, 8 = 8 hours per day, and 9 = 9 hours per day). The overtime premium is 50% of the calculated average of the regular pay.

232.01 / 34.75 = 6.6765 (6.68) 6.68 * 50% = 3.34

2.75 * 3.34 = 9.185 (9.19) The system is designed to calculate overtime for hours worked in excess of 40 hours worked less any holiday pay for a given week. If overtime pay were to be administered to an employee with less than 40 hours worked, it would have to be done manually. After entering these fields the user will be prompted to accept the entry or not. A <N>o will ignore everything just entered and return to the 'Enter Employee Code' prompt. Responding <Y>es will display the following message and then add the Time and Op Code fields to the screen:

One Moment While Updating File… When the user accepts the entry, there is a slight pause while the hours are written to a file. They are then presented with the total time entered above (Regular hours plus Overtime hours). This number can be changed for whatever time period is being entered. For example, if the operator had worked for 8 hours total, 2 hours Machine down time, 2 hours on Samples, and 4 hours on Piece Work. The user enters 2.00 then M for Machine down (if they do not know what the code should be, they can blank this field, and a browse window will pop up with all of the current codes. By choosing a code and pressing <Enter> the code will be automatically inserted). If an Off-Standard code is entered, the user will be prompted to pay at <A>verage, <M>inimum, or ase Rate. <A>verage pays at the operator's current average. <M>inimum pays at the rate code entered in the Master System Screen (1 of 7 rate codes. See Appendix A - Piece Work Payroll Rates on page 98). This is usually set at the Federal Minimum Wage. ase Rate is the default rate entered into the operator's master record. If a code, which begins with 'P' is entered, this indicates piece rate to the system. First, the user is prompted for a base rate (the default here is the rate number which is in System Flag 249). This can be accepted or changed. They can then either scan in tickets, or enter tickets manually. Alternately, the user

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can enter in a quantity and a SAM value to pay an operator for a block of time. In order to add/edit/delete any of the operation codes refer to the Utility manual under Code and Lookup Tables <U-4-8-4>. After entering the Time and Op Code, or pressing <Enter> to accept the defaults, the user will be prompted at the bottom of the screen as to what rate level to pay piecework at. The pay rate will then appear allowing for any changes. The following screen will then appear over the previous one (see Figure 2.1):

Figure 2.1: Daily Gross Pay Data Enter the necessary tickets at this point. Once complete pressing <Esc> will return to the 'Enter Employee Code' prompt. When finished, pressing <Esc> will prompt as to if the user wishes to Pack & Reindex the daily piecework file now. Regardless of whether the user responds <Y>es or <N>o they will be prompted as to if they wish to Pack & Reindex the hourly payroll file. If the user responded <N>o to both of the previous prompts, they will be returned to the Piecework Payroll submenu. If <Y>es was selected for either, the packing and reindexing will be performed and the user will be returned to the submenu. This option represents the whole purpose of the Piece Work Payroll System. This is where the user can scan and calculate Piece Work earnings for the operators. If tickets have been printed and placed in work, they can be scanned through this option. However, it is possible to calculate Piece Work with nothing more than an operators name and total earnings. The input system will accept a Manually entered Ticket / Sequence number, an Operation Code without a Ticket number, just a Style number, or just the quantity produced and the SAMs to apply. If a Ticket / Sequence number set is either scanned or entered manually and is valid, and not previously used, the system will automatically update the earnings and display the results in the box in the upper right hand corner of the screen. If the ticket has already been paid, the system will alert the user of such,

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but will not pay the ticket a second time. If a ticket or bundle has been voided or canceled previously (either manually, or by scanning in a '999' inventory ticket), it will alert the user, but will not pay the ticket. Otherwise, the system helps as much as it can. If a valid Operation Code is entered, the system will be able to display the SAM, which means that the operator will only have to enter the Quantity. If the Operations code is not valid, the operator will have to enter the SAM manually. The user must enter the employee in the Employee Master file (see Gross-to-Net Payroll manual) before they can enter any payroll information for that employee. If the user exits before completing an operator, the system will delete the operator's record from the file. The user should not escape out until the operator's earnings are complete for that day. They are not permitted to come back later and enter in additional tickets for the operator. Instead, they must reset the records for that day and key them in again. Sometimes, when this section is exited, the user will receive a notice asking about packing and reindexing the daily piecework file. The user should answer <Y>es to this unless they know that someone else is currently in the piecework section. This occurs when the system detects that there are empty records in the file and they need to be cleaned out.

Vacation/Holiday/Sick Pay This option permits the operator to enter Vacation, Holiday, and Sick Pay. Pay entered in these categories is entered in hours against a rate selected by the operator. Pay entered into these categories is maintained throughout the Piece Work and Gross-to-Net system for tracking purposes. However, the system does not have the mechanisms in place to police these special categories. The user may receive a prompt to create a holiday pay record for every employee. If <Y>es is selected the user will be asked if they want to create these records for all hourly employees and then every piecework employee. If <N>o is selected, or if your system is not setup to receive this prompt the following prompt will appear:

The name and social security number of the selected employee will then appear along with a prompt to ensure this is the correct employee. A <N>o response will return to the 'Enter Employee Code' prompt. A <Y>es will prompt for a work date, press <Enter> to accept the default of the current date or enter a new one. The following information will then be displayed on the screen:

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Once entering all of the required information the user will be prompted as to if they wish to accept what has been entered. Selecting <C>ancel will ignore all of the information just entered and return to the 'Enter Employee Code' prompt. A <N>o will return to the 'Holiday Hours' field for corrections to be made to the data previously entered. Responding <Y>es will accept the data entered and return to the 'Enter Employee Code' prompt. When finished, pressing <Esc> will return to the Piece Work Payroll submenu.

Reset/Delete Payroll Data It is necessary at times to undo what has already been done. This is the place. The user is first prompted to again enter a valid employee code and then a working date, regular hours/rate, and overtime hours/rate. They are then further prompted to confirm the day selected. A <N>o will return to the 'Enter Employee Code' command. A <Y>es will prompt one final time as to if they wish to delete the selected days piecework earnings. A <N>o returns to the Piece Work Payroll menu. A <Y>es will delete the Piece Work Earning, prompt if the user wants to pack and reindex now, and then return to the Piece Work Payroll menu. There are numerous reasons that a payroll might have to be recalculated. These include rate changes, errors in tickets, reporting errors, and many more we haven't thought of. This function allows the operator to undo a specific day, and as many days for as many operators as necessary. The tickets, previously scanned, are unmarked and returned to the Work-in-Process pool. THE FOLLOWING REPORTS LIST, EVALUATE AND SUMMARIZE THE EARNINGS ENTERED FOR THE WEEK-TO-DATE. THERE ARE NUMEROUS REPORTS THAT SERVE A VARIETY OF PURPOSES. IT IS RARE THAT A COMPANY WILL PRINT ALL REPORTS EVERY DAY OR WEEK. IN GENERAL WE EXPECT THE USER TO DETERMINE THE REPORTS THAT BEST SERVE THE PURPOSE AND TO PRINT THEM ON A CONSISTENT BASIS. IF DEPARTMENTS ARE ACTIVE ON YOUR COMPANY’S SYSTEM MANY OF THE FOLLOWING REPORTS WILL TOTAL AND SEPARATE ON DEPARTMENT CODES.

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Average Earnings Reports This option brings the operator to another menu that offers to print Four Week, Six Week, or Quarterly Average Earnings. The operator can also edit averages by selecting option ‘4’.

The average earnings are calculated by the system during the end-of-week update. It does not matter if the Gross-to-Net Payroll System is active. THE SUMMARY EARNINGS REGISTER WILL DISPLAY THE PIECEWORK EMPLOYEES HOURLY AVERAGE WHICH IS CONTROLLED BY THE SETTING OF FLAG 623 = Y.

Six-Week Running Average The first prompt that the user will receive, upon selecting option ‘1’, is the following:

Selecting <C>ancel will return the user to the Average Earnings Reports submenu. Regardless of whether <Y>es or <N>o is selected the user will then receive the standard printer report control prompt. An example of what will print is displayed below (see Figure 2.2):

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Figure 2.2: Six-Week Running Average

Four-Week Running Average This option, ‘2’, will perform the same as the previous one, except that 4 weeks will be displayed as opposed to 6.

Quarterly Averages Again, for option ‘3’ the same ‘Terminated Employees’ prompt, from option ‘1’ and ‘2’, will be displayed. However, the following is an example of what will print when prompted (see Figure 2.3):

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Figure 2.3: Quarterly Averages

Thirteen-Week Running Average Option ‘4’ will also perform as the previous ones did, however, reporting on 13 weeks as opposed to 4 or 6.

Edit Averages Selection ‘5’ will display the following screen after a valid employee code is entered:

Selecting <E>dit will place the cursor in the first ‘$/Hr’ field. Once completed editing averages pressing <Esc> will prompt if the user wants to update the employee master file and then returns to the Average Earnings Report submenu.

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Quick Average Update The first prompt that the user will receive, upon selecting option ‘6’, is the following:

After entering a valid employee code the following screen will be displayed:

The cursor will be in the ‘Elapsed SAM’ field. Make any necessary changes and after entering in the effective rate the user will be prompted as to if they wish to update this employees averages. Both responses will return to the ‘Employee Code’ prompt, however, <Y>es will first save the changes to the employees file. Pressing <Esc> will then return to the Average Earnings Reports submenu.

Initial System Setup The first prompt that the user will receive after selecting option ‘7’ is for a valid by-pass code. After entering the code the user will receive the following prompt:

The user will want to respond <N>o to this unless they have been otherwise instructed.

Add/Edit Payroll Subsidy The first prompt that will be displayed upon selecting option ‘8’ is:

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After entering a valid employee code the user will be prompted to enter the Payroll Hourly Subsidy and press <F10>. Once complete the user will be returned to the Average Earnings Reports submenu.

Recalculate Last Quarter Average THIS OPTION IS AVAILABLE BY SPECIAL ORDER. CONTACT YOUR SOFTWARE VENDOR FOR ADDITIONAL INFORMATION CONCERNING THIS AREA.

Gross Pay Register (Summary) This is a duplicate of the Gross Pay Register from the Gross-to-Net Payroll Program. The sole purpose of this report is to document the week-to-date Gross Pay. This Report deals with Hours and Dollars. This includes Regular, Overtime, Vacation, Sick, and Holiday Hours and the pay resulting from each group of hours. Makeup is noted as a gross amount and will include training allowance if System Flag 363 is turned on. The first prompt the user will receive once choosing ‘5’ on the Piece Work Payroll menu is:

Upon entering a valid Employee Code the user will receive the standard printer report control prompt allowing for printing to screen or printer. When printing is complete the user is returned to the Piece Work Payroll submenu. An example of what will print is displayed below (see Figure 2.4):

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Figure 2.4: Gross Pay Register (Summary)

Gross Pay Analysis (Detailed) The Detailed Gross Pay Register is similar to the Summary Gross Pay Analysis. However, this report adds the Pay Category and Percent Efficiency for Piece Work Earnings. The user will first be prompted to enter a valid Employee Code. Then receive the standard printer control or the option to send to screen or printer. When printing is complete they will be returned to the Piece Work Payroll submenu. An example of what will be displayed on the screen or printed to the printer is shown below (see Figure 2.5):

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Figure 2.5: Detailed Earnings Analysis

Earnings by Operator The Detailed (Daily) version of this report lists the date, Operation Code, Number of Bundles, Quantity, Earned Hours, Clock Hours (Elapsed Hours), and Percent Efficiency. The Summary (Weekly) Report eliminates the date and Operation Number. The user is first prompted:

<D>aily or <W>eekly Earnings (or <Esc>) _ Regardless of whether they choose Daily or Weekly Earnings by Operator the user will receive the standard printer report control prompt. When the printing is completed the user be returned to the submenu. An example of what will print is shown below (see Figure 2.6):

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Figure 2.6: Earnings by Operator

Coupon Register by Operator This report is NOT for every company. It is a list of all coupons scanned into the system. Obviously, this can use a lot of paper. It simply prompts the user with the standard printer report control prompt for a complete printout of the Coupon Register by Operator. The user will be returned to the Piece Work Payroll submenu when complete. An example of what will print is displayed below (see Figure 2.7):

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Figure 2.7: Coupon Register by Operator

Production Summary Report This report provides the means to review the plant performance as specified for a particular Style, Class, or Cut for any given date range. This report reflects the Earned Hours and Total Hours, the Earned Pay, and Total Pay that has been associated with each of the report criteria. The content of the report provides the Earned Hours and Pay, then a detailed breakdown of the off-standard hours and pay by category. From this performance related data, a number of calculations are shown for such items as Plant Efficiency, Hourly Pay Rates by category, and Unit Costing versus standard. There are three flag settings that relate specifically to the functioning of this report: 493 - By setting this flag to ‘Y’ it will make a Reference field available each time an off-standard pay category is entered during the daily Gross Pay entry. By entering a style number, the off-standard pay for that entry can then be associated with that particular style. Without making this entry, the report will not associate the excess cost with a particular style, thus negating the use of this report. If making this extra entry for each off-standard occurrence is viewed as being too time consuming, then this report should be excluded from the normal routine. 475 - This flag is used for providing Alternate piecework operations in the style breakdown. In

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determining the standard for the SAM and direct labor cost per unit, only the Primary operations will be counted. The Alternate operations will not be used in calculating the standard. 275 - The setting for this flag determines whether the system is based on Pieces, Dozens, or Hundreds. This is necessary since the cost figures for both the standard and actual will only reflect a PER UNIT calculation. This is a performance related report and since it is associating off-standard categories to specific styles, this should not be confused with a Standard Excess Cost report. Although the format of this report closely resembles that of as Excess Cost Report, by providing the date range criteria there are certain excess costs that are normally calculated that will not be reflected in this report. Specifically, Makeup, Training Allowance, and Overtime Premium are normally being calculated daily or weekly and as a result will not be included in this report regardless of the criteria selected. Only the off-standard categories that are referenced to a time element as a criteria will be shown on the report. By leaving the reference field blank during the entry of the off-standard time, that particular off-standard entry will then be excluded from the report totals. This would be considered for codes not directly associated with production performance, such as Meetings, Inventory, and Ergonomic Exercises. The actual versus standard comparisons will be made based on the following parameters: Quantity Produced Actual - units scanned into the inventory via the ‘999’ ticket Standard - the total units from the cutting order associated with the style Unit Production Time Actual - total clock hours divided by actual units Standard - total SAM taken from the style breakdown Unit Direct Labor Cost Actual - total reported pay divided by actual units Standard - total cost per unit from the style breakdown Unit Overhead Cost Actual - unit direct labor cost times the overhead factor taken from the cost sheet Standard - standard cost per unit times the overhead factor taken from the cost sheet Unit Material Cost Actual - unit material cost taken from the cost sheet Standard - same as Actual The first prompt that the user will receive upon selecting option ‘9’ is for the date range for the report. Once the beginning and ending dates have been entered for the report the user will be prompted for the style #, class, cut order, base rate, overhead rate and given the option to run the report. Once ‘Run Report’ has been selected the user will receive the Windows Printer Dialog box. Once the report has completed printing the user will be returned to the Piece Work Payroll submenu.

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Efficiency Week-to-Date When the user selects ‘A’ they will first be prompted:

Efficiency by <S>tyle, <O>peration, <C>ut (or <Esc>)? _ All three of these options prompt the Windows Printer Dialog box and then return the user to the Piece Work Payroll submenu. Efficiency Reports can be printed by Style, Cut, or Operation. All of the reports list the Employee, Quantity Produced, Earned Hours, Clock Hours, and Percent Efficiency. The <S>tyle option will sort by style numbers (and departments, if applicable), <O>peration will sort by operation, and <C>ut will sort by the Cut/Lot # (and departments if applicable). The information presented includes both scanned and manually entered data. The second prompt that the user will receive is the following:

If the user wishes to quit at this point they may do so by selecting <Q>uit. Selecting <C>urrent will proceed and prompt the standard printer report control prompt. Selecting <A>rchive, on the other hand, will prompt for a ‘Beginning’ and ‘Ending’ date and then prompt for the printer. The following example is similar to what would print if <O>peration was selected as the sort method and <C>urrent was selected as the basis for the report (see Figure 2.9):

Figure 2.9: Efficiency by Dept/Operation

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Exception Pay by Operator This report lists Exception and Piece Work Pay by Operator, summarized on a week-to-date basis and shows the percent efficiency. The users only prompt upon selecting option ‘B’ will be the Windows Printer Dialog box. Once the printing is complete they will be returned to the Piece Work Payroll submenu. An example of what will print is displayed below (see Figure 2.10):

Figure 2.10: Exception Pay Analysis

Weekly Processing Upon selecting option ‘C’ the following submenu will appear:

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Recalculate Week-to-Date Makeup This function does exactly what it says. As the earnings are scanned into the computer, the program calculates daily makeup as a guide to overall performance. However, since most plants pay weekly makeup, this option recalculates the entire week as a whole. Upon selecting option ‘1’ the user will be prompted as to if they wish to print a makeup register. Selecting <C>ancel will return the user to the Weekly Processes submenu. A <N>o will prompt 'CALCULATING MAKEUP'. The user can then use the arrow keys or press <Enter> and they will scroll through the employee listing showing: TOTAL ELAP., EARNED HRS., ALLOWANCE, and EMPLOYEE CODE. Once complete the user will be returned to the Weekly Processes submenu. Responding <Y>es will prompt the standard printer report control prompt (the final printout is shown in Figure 2.11), then the user will be shown the listing of employees.

Figure 2.11: Makeup Calculation

The user will then be returned to the Weekly Processes submenu as the printer prints out the makeup register.

Weekly Overtime Exception List This is a list of the operators who are getting overtime premium and haven't worked 40 hours. It also lists operators who have worked over 40 hours, and aren't getting overtime premium. Upon selecting ‘2’ from the Weekly Processing submenu the user will receive the prompt:

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Upon entering a valid Employee Code the user will further be prompted:

Following is an example of the printout of the Weekly Overtime Exception List (see Figure 2.12):

Figure 2.12: Hours/Overtime Register

When completed or upon entering an invalid Employee Code the user will be returned to the Weekly Processing submenu.

Automatic Overtime Calculation This function will modify your company’s payroll files in the way overtime is calculated and paid. For example, suppose an operator worked 9 hours each day, and that as the operator keyed each day in, they gave her 8 hours at regular time plus 1 hour overtime. This program will accumulate all of the time as

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regular time then apportion off any hours over 40 into the overtime field (and of course pay the overtime premium for each hour over 40). By printing the Summary Gross Pay Register (see pg. 65) before running this module, then printing it again after this has been run, the user will be able to see it's effects on overtime and gross pay. SINCE THIS MODULE CHANGES YOUR COMPANY’S PAYROLL FILES, THE USER SHOULD MAKE A BACKUP OF THE DATA FILES BEFORE RUNNING THIS PROGRAM. IF SOMETHING HAPPENS WHILE THIS MODULE IS RUNNING (A POWER FAILURE FOR EXAMPLE), THEN THE USER CAN RESTORE FROM THE BACK UP AND RUN AGAIN. WITHOUT A BACKUP, THIS MODULE IS NOT REVERSIBLE. Upon selecting this option the user will receive the following prompt:

A <Y>es will calculate the overtime and then return to the Weekly Processing submenu, while a <N>o returns to the submenu.

Gross Pay Register [Summary] This option begins by prompting for the Employee Code to base the report on and then prompts the standard printer control, allowing for the report to be sent to the screen or printer. Once complete the user will be returned to the Weekly Processes submenu.

Detailed Weekly Payroll Analysis Option ‘5’ from the Weekly Processes submenu begins by prompting the following:

Selecting ‘OK’ then prompts for the Employee Code to use in the analysis. After selecting a valid employee the user will be prompted if they only wish to show one operator by page and then if they wish to report by department. Finally the printer control box will appear allowing for the report to be sent to the screen or printer. Once complete the user will be returned to the Weekly Processes submenu.

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Export (Bridge) Payroll to ADP THIS OPTION IS AVAILABLE BY SPECIAL ORDER. CONTACT YOUR SOFTWARE VENDOR FOR ADDITIONAL INFORMATION CONCERNING THIS AREA. The first prompt that the user will receive upon selecting option ‘6’ is a confirmation that they indeed wish to bridge the piecework payroll to the ADP PC payroll program. The specified file name is the name of the file that the user specifies in the ‘ADP Payroll Data’ field of the ‘Payroll’ tab under <U-4-1> - Additional Utilities, Company Defaults (refer to the System Utility manual for more information). This file location can also be found and updated in Piece Work Utilities at <Y-A-B-2> on page Error! Bookmark not defined. of this manual. If the user answers <Y>es, the system proceeds with the exporting of data. If <N>o is selected they will be returned to the Weekly Processes submenu.

Update Gross-to-Net Payroll File This is the last direct Payroll function in the Source-to-Gross system. This selection, ‘7’, passes the Gross Pay to the Gross-to-Net System; calculates the Averages for the Current Week, Quarter, and Year-to-Date; Archives the Completed Coupons; Increments the Week and Quarter (if applicable) Counters in the Company Master File; and finally resets the files for a new week. If your system has Capacity Planning turned on, that file will be automatically updated at this time. The first prompt that the user will receive is:

A <N>o will send the user back to the submenu, while a <Y>es will further prompt:

A <Y>es will continue and update the file. A <N>o, on the other hand, will prompt the following:

The user will then be returned to the Weekly Processes submenu. Responding <Y>es will display an ‘Updating Payroll...’ message and then return the user to the Weekly Processes submenu.

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Bundle Maintenance Functions This option, ‘D’ is the same one that appears under the Piece Work Tickets submenu, option ‘8’. For further information please refer to that section on page 41 of this manual.

Capacity Planning THIS OPTION IS AVAILABLE BY SPECIAL ORDER. CONTACT YOUR SOFTWARE VENDOR FOR ADDITIONAL INFORMATION CONCERNING THIS AREA. This module, option ‘P’ allows you to enter in projected plant capacity, then takes actual piece rate data and creates a report showing Plan vs. Actual performance. When the user chooses this function, it will bring up the submenu shown below:

Capacity Planning Weekly Report This option prints the weekly report, which shows Standard Direct Labor Hours Earned, Actual vs. Planned. It includes the number of piece work operators for the week, the effective attendance rate, the average operator efficiency (total), number of work days for the week, standard hours earned, and a variance on past weeks, actual to planned. The first prompt that the user will receive is for the beginning and ending dates to be used for the report. Option ‘3’ (List Capacity Plan Schedule) can be used to view the dates. Some clients only plan 3 to 6 months ahead, while others plan one year in advance. For more on this file, please see the next section. Once a valid date range has been entered, the following report will be displayed on the screen (see Figure 2.14):

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Figure 2.14: Weekly Capacity Planning

Operator Headcount - The total count of persons on piecework. Effective Attendance - The percentage of actual hours worked vs. the number of hours worked if everyone on piece rate worked a full week (8 hours per day times the number of days planned). If Saturday is not counted in the Planned Days, then it will have a positive contribution to this figure. Operator Efficiency - Calculated as Hours Earned divided by Hours Worked. Work Days - Counted as 8 hours per day. Sdl Hours Earned - Standard Direct Labor hours. In the Plan, it is calculated as headcount X Effective Attendance X Operator Efficiency X Work Days X 8 hours per day. In the Actual, it is simply the Hours Earned from the piece work data file. Variance To Plan - Actual SDL Hours Earned divided by Planned SDL Hours Earned.

Modify Capacity Plan Schedule This option allows the user to enter in advance planning information. Actually, the user is not restricted to forward movement only, they are allowed to move backwards through the file if they desire. When they take this option, they are presented with the entry screen shown below:

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This screen starts with the first day of the current workweek. The user enters in any date they want and the system will change the date to the first day of that workweek. The counter in the center (Weeks Forward) indicates how many weeks in advance the user is at (compared to the current week). For easier navigation, they can use <PageDown> to go forward by one week, <PageDown> to go backwards by one week. Also, <End> will take the user to the last week they currently have in the file, while <Home> will take them to the first week on file. When the user begins entering in additional weeks, the rest of the fields default to the settings of the previous week, but the user is free to change them, or just hit <Enter> to accept them. When the user lands on a week, which has already been entered, they are presented with the current settings in the file for that week. They are free to make any necessary changes. When complete, pressing <Enter> in the last field will further prompt if it is OK to save the file. Selecting <C>ancel will ignore anything just entered and return to the Capacity Planning submenu. Pressing <N>o will return to the beginning for reentry and <Y>es will save the data and return to the Capacity Planning submenu.

List Capacity Plan Schedule This will display the settings of the file on the screen for the user (beginning with the first week in the file, and progressing one screenful at a time to the end of the file). It is convenient to use if they want to make a quick check of the settings for any week(s) in the file, without going into the editing screen. An example of the screen that will be displayed is shown below (see Figure 2.15):

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Figure 2.15: Capacity Planning Schedule

Capture Past Payroll Data The first prompt that the user will receive upon selecting option ‘4’ is for the beginning and ending dates for the payroll data they wish to capture. When the user first begins, there will not be any past piecework data in this file. However, they may already have several weeks or months of past data. This allows them to capture that data into this file, one week at a time. Enter any date within the week to capture, and it will back up to the first day of that workweek, then capture the earned and elapsed time. When the payroll department closes out the week, the planning file will automatically be updated. This function is normally used when the user first gets setup then rarely used. It is handy if something goes wrong with the automatic capture (linked to the Gross-To-Net payroll function), and the planning file doesn't get updated.

Report Excess Dollars by Category This report uses the archived piecework data. Please note that if a week is still being worked on by the payroll department it will not be available for this report. Upon selecting option ‘5’, the user will receive a prompt asking if they want a new page for each department. The users response will not affect the next prompt, it only determines if departments will be on the same or separate pages.

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The next prompt will then be for the beginning date of the last week. This date can be any valid date within the workweek they wish to report on. It will try to report on the 5 previous weeks also, but if any of those weeks do not exist (as when the user first begins to use our payroll system), then the reporting period will be shortened. The report attempts to give a 6 week 'Rolling Average', but if it can only find 4 weeks worth of data, then the time period for the rolling average will change to 4. If the user enters a date for which it cannot find any records, then it will alert the user to that, then return to the submenu. The first time the report is run, the user may notice that a department appears to show up 2 or more different times. Please note that the department field in the operator's record is a text field. If the user enters Operator A as being in Department '_2' and then Operator B as being in Department '2_', then the report will show the user 2 different departments. Please be careful when entering the departments on the operator's record. The report may take some time to run, depending on the size of the archived file, and how many operator records it finds. It may take several minutes before allowing the user to choose a printer, so please be patient. The report shows dollars, but a future version may give the user the option of showing dollars or hours. The first category is the Standard Direct Labor Dollars Earned on piece rate (all types of piece rate codes). The next category is Makeup (all codes). Next is the Training Cost differential (if your company has that feature turned on). This is the excess between what the operator earned, and what was paid under the terms of the training codes. After that, the remaining codes which were in use for that department for the entire reporting period. The excess costs are subtotaled then the Standard Direct Labor Dollars are added to give a Total Department Cost. The last item to appear under the department is the Cost per Standard Dollar. It is calculated as the total $ paid (the sum of all of the above figures) divided by the Standard Direct Labor Earned Dollars. A figure of $1.20 means that it cost $1.20 to get $1.00 worth of product. After all of the departments have been reported, they are summarized for a total plant picture. Then each department is shown with a calculated operator On-Standard Efficiency %, and an Average Operator Earnings for the Current Week. A comparison of this report with 2 other payroll reports may need some explanation. If the user looks at the Gross Pay Register (Summary), as explained on page 61, they will notice that the Department and Report Totals Gross, should match the totals on this report. On the above Gross Pay Register, M/U Pay is made up of Makeup + Training Costs on this report. Regular Earnings on the Gross Pay Register is made up of Std Direct Labor $ + all other excess costs (except for Makeup, Training Costs, and Overtime Premium) on this report.

Verify Coupon Status

Upon selecting option 'V' the following prompt will appear:

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If the user selects <S>ingle Coupon the following screen will be displayed (see Figure 2.16):

Figure 2.16: Verify Coupon Status – Single Coupon

After entering a valid ticket/sequence number combination the remaining fields will be filled in as this sample shows. Notice that the bottom of the screen instructs the user as to how to respond for the current field. After reviewing the coupon, pressing any key will return the user to the original screen, prompting them to enter a ticket (coupon) number. Once complete, pressing <Esc> will return the user to the Piece Work Payroll submenu. If the user selected <E>ntire Bundle they will be prompted for which bundle they wish to lookup. After entering a valid bundle ticket and pressing <F10> the following screen will be displayed (see Figure 2.17):

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Figure 2.17: Verify Coupon Status – Entire Bundle

Once complete, pressing <Esc> will return to the Piece Work Payroll submenu.

Vac/Hol/Sick Summary Report The only prompt that the user will receive, upon selecting option ‘S’, is for the beginning and ending dates for the summary report. Once valid dates have been entered the user will receive the Windows Printer Dialog box. After printing the report the system will return to the Piece Work Payroll submenu.

Cutting/Warehouse Incentive Entry THIS OPTION IS AVAILABLE BY SPECIAL ORDER. CONTACT YOUR SOFTWARE VENDOR FOR ADDITIONAL INFORMATION CONCERNING THIS AREA.

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PIECE WORK UTILITIES Upon selecting the option for Piece Work Utilities from the Main Payroll menu, the user will receive the following submenu:

Payroll Printer Codes This function allows the user to setup printer codes and select the default printer. When option ‘1’ is selected the following submenu will appear:

Ins ta l l P r in te r Con t ro l Codes Function ‘1’ provides the user with the ability to modify the printer codes that control various printer functions, such as, compressed printing, form lengths, line spacing, and printer initialization. The user may want to note that all printer codes are NOT located here. We decided to split the data into areas of interest. In other words, the codes required for Garment Care Labels are located in that program module, as are the codes for Invoice and Statement printing are located in the Utility module. Based on your requirements, the user can even leave selected codes blank in order to eliminate the effect of certain codes on your system. For instance, if the user does not like the compressed reports, and always remember to keep wide paper in the printer, this code can be left blank. ALL OF THE PRINTER CODES THAT FOLLOW MUST BE ENTERED IN 'DECIMAL' FORMAT, OR THE SYSTEM WILL NOT INTERPRET THEM CORRECTLY. MOST PRINTER MANUALS WILL PROVIDE THESE CODES IN DECIMAL AS WELL AS HEXADECIMAL FORMAT.

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The samples listed below are from the Epson FX Series manuals which lists the Compressed printing code as either ‘SO’ (Shift Out) or as CHR$(15). The use of the ‘$’ in the second command is the BASIC language designation of the decimal command. AS/AP™ uses a similar designation WITHOUT the ‘$’. Therefore, the Epson code for compressed printing is entered as: CHR(15) for the AS/AP™ system. If the user has any difficulty with these codes, contact your software dealer or consultant. For further information, refer to the Appendix on Printers in the System Utility Manual. RESET PRINTER - Most printers have a reset code, which will place the printer in the original mode during its' power-up. Enter the appropriate printer code used to reset the printer. On an Epson printer, the code, in decimal format, would be: CHR(27)+CHR(64). RESET FORM LENGTH - This code represents the standard length of forms used in the printer. Enter the appropriate printer code for the length of the standard paper used. COMPRESSED PRINT - Enter the appropriate printer code for printing in compressed form. Some reports require compressed printing to fit on 8-1/2" paper. If the user wants to use the 14" paper for those reports, skip this field. All the manuals, in the appropriate sections, will tell the user, which reports require 132 print positions. If unsure of the correct printer code, contact your software dealer or consult-ant. CHECK LENGTH - Enter the appropriate printer code for the length of the check forms. The standard check format sets the printer form length to 7 inches. On an Epson printer, the code, in decimal format, would be: CHR(27)+CHR(67)+CHR(42). The last number, '42' is derived from the fact of having 6 lines per inch, and a form of 7 inches (i.e. 6x7=42). If the program needs to be modified to use non-standard forms, these form lengths will have to be changed. However, both the A/P and Payroll checks must be the same length. EXPANDED PRINT - Enter the appropriate printer code for printing in expanded form. If unsure of the correct printer code, contact your software dealer or consultant. PIECE WORK TICKET PAGE - Enter the appropriate printer code for the length of the piecework tickets sheets. The standard ticket is 2 1/2" wide by 15/16" high - 3 across. On an Epson printer, the code, in decimal format, would be: CHR(27)+CHR(67)+CHR(18). The second layout is 2 1/2" X 3/4" - 3 across. However, this is NOT a Standard Label, and must be purchased direct from the manufacturer or through AS/AP™. These labels are color coded, pre-drilled for tie strings, and made of heavy weight stock. The first prompt that will appear after selecting option ‘1’ is the following:

After the user selects the desired printer and presses <F10> the following ‘control codes’ screen will appear:

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Once complete, the user will be prompted as to if they are finished, giving them the option of returning to the printer controls. A <C>ancel will ignore everything just entered and return to the Printer Codes submenu. A <N>o will return to the beginning field allowing for reentry and <Y>es will save the data and return to the submenu.

Selec t P r in te r THIS OPTION IS ONLY AVAILABLE UNDER THE DOS SHELL. CONTACT YOUR SOFTWARE VENDOR FOR ADDITIONAL INFORMATION CONCERNING THIS AREA.

Conf igure HP LaserJe t THIS OPTION IS ONLY AVAILABLE UNDER THE DOS SHELL. CONTACT YOUR SOFTWARE VENDOR FOR ADDITIONAL INFORMATION CONCERNING THIS AREA.

Build Payroll Indexes This function allows the user to re-index the Payroll files that have either lost their index or had an index damaged. NO OTHER TERMINAL SHOULD BE IN THE PAYROLL MODULE WHEN RUNNING THIS OPTION!! When the user selects option ‘2’, the screen will clear and a reindexing message with the name of the database being reindexed will be displayed. When the reindexing is complete, the user will be returned to the Payroll Utilities submenu. Even if rebuilding the indexes clears up the problem(s), the System Messages should be reported to Software Support.

Build Piecework Indexes This function allows the user to re-index the Piece Work Payroll files that have either lost their index or had an index damaged. NO OTHER TERMINAL SHOULD BE IN THE PAYROLL MODULE WHEN RUNNING THIS OPTION!!

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When the user selects option ‘3’, the screen will clear and a reindexing message with the name of the database being reindexed will be displayed. When the reindexing is complete, they will be returned to the Piece Work Utilities submenu. Even if rebuilding the indexes clears up the problem(s), the System Messages should be reported to Software Support.

PW System File Update When option ‘4’ is selected, the system will prompt to ensure that there are no other stations in the PW system. Selecting <N>o will return to the Piece Work Utilities submenu. Selecting <Y>es will clear the screen and display an 'Updating Files...' message. NO OTHER TERMINAL SHOULD BE IN THE PAYROLL MODULE WHEN RUNNING THIS OPTION!! When the updating is complete, the user will be returned to the Piece Work Utilities submenu.

Pack and Reindex Files This is a maintenance function that is not necessary unless the user chose to NOT Pack and Reindex the files as other options were completed. If there are still files that have not gone through the Packing and Reindexing stage then it is necessary to do so now. Upon selecting ‘5’, the following prompt will appear:

A <N>o will display 'Processing Ticket File...' and that the packing and reindexing is affecting only the current files. A <Y>es will display 'Deleting Cancelled Tickets...' will it is packing and reindexing the files. When packing, reindexing, and possibly deleting is complete, the user will be returned to the Piece Work Utilities submenu.

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Labor Cost Analysis THIS OPTION WAS CUSTOM DESIGNED FOR A CLIENT AND MAY NOT FUNCTION PROPERLY IF YOUR CONFIGURATION IF DIFFERENT FROM THEIRS. FOR ADDITIONAL INFORMATION ON THIS TOPIC CONTACT YOUR SOFTWARE VENDOR. The Cost Analysis is designed to automate the task of labor costing by updating the Bottom Line to reflect changes in the Direct Labor SAM or Base Rates. "Cutting", "Indirect" Labor, and "Misc. Cost" are Fixed costs which remain constant unless individually edited. The Overhead factors can be either Fixed or Variable depending on the way in which the operator answers the questions. If percentages are entered in the right hand columns, the operator isn't allowed to enter a fixed overhead amount. If the percentages are left at zero, fixed amounts can be entered. The first prompt the user will receive after selecting ‘6’ from the Piece Work Utilities submenu is for a style number. Upon entering a valid style number the labor cost screen will be displayed along with a prompt to update the file. Selecting <Q>uit will return to the 'Style' prompt. Responding <N>o will return to the above screen allowing for corrections to be made. A <Y>es will update the file and return to the 'Style' prompt. Once complete, pressing <Esc> will return to the Piece Work Utilities submenu. The results of the Labor Analysis can be printed on the Garment Breakdown. Which is found on the Piece Work Ticket Menu, Piece Work Reports.

Purge Cancelled Tickets The Finished Goods Inventory Program is able to scan ‘999’ tickets as production is received into the Finished Goods warehouse, or whatever checkpoint the company wishes to establish. When the file is updated and posted against the Cutting Ticket, the system cancels any Operational Tickets that have still NOT been claimed. The canceled tickets are not immediately removed from the file for several reasons. If we remove them and an operator turns a ticket in the next day, we would not be able to tell why the ticket was not available. By marking it cancelled and leaving it in the WIP File, we are able to report to the computer operator that the ticket was canceled. However, we must eventually clear those excess tickets from the file. This function does just that. By selecting ‘7’ from the Piece Work Utilities submenu the following prompt will appear:

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A <Y>es displays a 'Clearing Canceled Tickets...' message and then returns to the Piece Work Utilities submenu. A <N>o will send the user directly to the Piece Work Utilities submenu.

Piece Work Op Codes/Training Allowance Chart Upon selecting option ‘8’, the following submenu will appear:

The Work Codes, also known as Off-Standard Codes, can be set up using selection ‘1’ from this menu, Add/Edit Off-Standard Codes. Off-standard situations can be widely varied, and that is what the AS/AP™ system will allow to be setup through the work code (off-standard code) table. The AS/AP™ Piecework System is designed around the concept that on standard is entered as work code ‘P’ by itself. All other work codes beginning with ‘P’ permit coupon earnings to be entered, but the resulting earnings are classified as off standard. The system uses codes that begin with ‘P’ to allow the entry of coupons that can be associated with an off-standard category. For example, ‘P1’ is Transfer at Average in this code table with ‘A’ for Average as the basis of pay. This will allow the entry of coupons during the time period designated for this pay code. The operator will be paid Average or the coupon earnings whichever is higher. Off-standard codes that do not begin with ‘P’ will only allow a time entry coupons cannot be scanned against those codes.

Add/Ed i t O f f -S tandard Codes The first screen that the user will receive, following the selection of option ‘1’, is the following (see Figure 3.1):

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Figure 3.1: Piece Work Op Codes

To edit a code, simply highlight it and press the ‘Edit Code’ button in the toolbar at the bottom (shown to the left). The fields at the bottom of the screen will then display the current information allowing for changes to be made. Once complete press the ‘Save’ button at the bottom or the ‘Undo’ button if the user does not wish to save the changes. If the user wishes to delete a code, highlighting the line and pressing the ‘Delete Code’ button will do so (shown to the left). The user will then be prompted as to if they indeed want to delete the selected code. Selecting <N>o will return to the Code Table without deleting the selected code. A <Y>es on the other hand, will delete the record and return to the table. To add a new code, press the ‘Add Code’ button. The fields at the bottom will then be highlighted allowing the user to enter all applicable information. Press the ‘Undo’ button to cancel and not save the changes or the ‘Save’ button at the bottom to continue and save the new code. The user will then be prompted as to if they wish to write the code to the file. If everything entered is correct, select <Y>es and the code will be added to the table and the user will be returned to the ‘ADDING NEW RECORDS TO TABLE’ prompt for another entry. When complete, pressing <Esc> will return to the code table. If the user decides that they do not wish to add the code, selecting <N>o will ignore anything entered and return to the code table. Once complete, pressing <Esc> from the code table will return to the Piece Work Op Codes submenu.

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Ut i l i t y Opera to rs – Ca lcu la ted Sp l i t The training and off standard code table <Y-A-8-1> (found on page 89 of this manual) allows the user to enter the basis of pay to be used. The standard available codes are ‘A’ for operator’s average, ‘B’ for base pay, and ‘M’ for minimum. The ‘C’ indicates a split incentive with a variable rate level. The ‘C’ allows the system to calculate the EARNED minutes as a percentage of the coupon value, and the ELAPSED time as a percentage of the RATE LEVEL from the operation. That means that if an operation uses RATE LEVEL #5, and RATE LEVEL #5 is 6.20 per hour, the ELAPSED time will be calculated as a percentage of 6.20. In the situation where several different operations are being performed with many different RATE LEVELS, the program will calculate an AVERAGE of the different RATE LEVELS, which is used for both the EARNED minutes and ELAPSED time. Any off-standard piecework code that uses ‘C’ as a BASIS of pay, will include both the EARNED minutes and the ALLOWED earnings in the calculation of the employees’ on-standard average. By having off-standard codes with a ‘C’ BASIS of pay, the system will calculate the split incentive and the quarterly average for the utility operators directly without any additional outside calculation being required to adjust weekly earnings.

L is t O f f -S tandard Codes The only prompt that the user will receive, upon selecting option ‘2’, is the Windows Printer Dialog box. Once the printing is complete, they will be returned to the Piece Work Op Codes submenu. An example of what will print is shown below (see Figure 3.2):

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Figure 3.2: Off-Standard Codes

Qual i t y Aud i t Reason The first prompt that the user will receive, upon selecting option ‘3’ is:

Selecting rinter will display the Windows Printer Dialog box. Once the printing is complete the user will be returned to the submenu. If <S>creen was selected then the following Quality Audit Type screen will appear (see Figure 3.3):

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Figure 3.3: Quality Audit Type

The options for editing, deleting, and adding records are similar to those shown in option ‘1’ on page 89. Once complete, pressing <Esc> will return to the Piecework Op Codes submenu.

Qual i t y Aud i t Loca t ion This option, ‘4’, receives the same prompts as the two previously discussed options, however the screen that is displayed if <S>creen is chosen is the following (see Figure 3.4):

Figure 3.4: Quality Audit Stage

When complete, pressing <Esc> once again will return to the Piecework Op Codes submenu.

Mach inery and Group Codes Upon selecting option ‘5’ from the Piece Work Op Codes submenu the following screen will be displayed (see Figure 3.5):

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Figure 3.5: Machine/Group Codes

This is the first step when preparing the Work-In-Process Scheduling. Here the user sets up the equipment codes and the projected number of operators available for each code. It is important to note that this table does not print out the ‘Available’. Again, the user has the same options to add, edit, and delete codes as in the previous options. Once complete, they will be returned to the Piece Work Op Codes submenu.

Machine Downtime Analysis THIS OPTION IS AVAILABLE BY SPECIAL ORDER. CONTACT YOUR SOFTWARE VENDOR FOR ADDITIONAL INFORMATION CONCERNING THIS AREA.

Edit Base Rate Table(s) The first screen to appear upon selecting option ‘0’ is (see Figure 3.6):

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Figure 3.6: Edit Base Rate Table

Pressing <Esc> at this point will return to the Piece Work Utilities submenu. Selecting <E>dit will place the user at the Rate 1 field allowing them to edit any necessary fields. Entering a number between 0 and 9 will allow them to scroll through the various company’s base rates. IF MULTIPLE COMPANIES ARE NOT ACTIVE ON YOUR SYSTEM A MESSAGE TO THIS EFFECT WILL BE DISPLAYED. Once complete, pressing <Esc> will return to the Piece Work Utilities submenu.

Bar Code Printer Test The first prompt that the user will receive upon selecting option ‘A’ is to select the printer that they wish to use to test the bar code printing. Once the testing of the printing is complete the user will be returned to the Piece Work Utilities submenu.

Company Defaults This function is pulled straight from the System Utility module. Please refer to the Additional Utilities section of that manual for more information.

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Update Employee Departments

Upon selecting option ‘D’ the following prompt will appear:

Selecting <Y>es will begin by updating the file. Both responses will return the user to the Piece Work Utilities submenu.

Purge Old Data Option ‘P’ will prompt the following:

Both responses will return the user to the Piece Work Utilities submenu. Selecting <Y>es will first purge the data.

Run PW File Integrity Test Selecting option ‘T’ will simply run the integrity test and return the user to the Piece Work Utilities submenu.

Update Data Files The first prompt that the user will receive after ‘U’ has been selected is the following:

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A <N>o will return to the Piece Work Utilities submenu. A <Y>es, which will only be selected if the user is instructed to do so, will further prompt for the name of the file to run. After pressing <F10> the file will run and the user will be returned to the Piece Work Utilities submenu.

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APPENDIX A: PIECE WORK PAYROLL RATES The user can access the 7 Base Rate Levels by selecting the option 'Master File Maintenance' from the Utility Menu or through the ‘Company Master’ button on the toolbar if active on their system. The PW Rates can be found under the ‘Payroll Defaults’ tab of the company master file. They can enter up to seven different levels of Piece Work rates, which can be changed at any time. Generally, Rate 1 is used for the Federal Minimum Wage. When entering Gross Payroll Data for an operator, if an Off-Standard pay code is chosen, and <M>inimum is selected as the pay basis, the rate the user has entered here in Rate 1 will come up. A number entered into System Flag 249 (from 1 to 7) corresponds to the rate code here, which will come up as the default for Piece Work tickets. Although these Rate Levels may, in some ways, be synonymous with Skill Groups, the AS/AP™ Accounting System has an additional provision to maintain and track Skill Groups separately from the Rate Levels. Skill Groups are not presently in use.

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ALTERNATE OPERATIONS


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APPENDIX B: ALTERNATE OPERATIONS THIS OPTION IS AVAILABLE BY SPECIAL ORDER. CONTACT YOUR SOFTWARE VENDOR FOR ADDITIONAL INFORMATION CONCERNING THIS AREA. To begin with, the following screen shows the ‘Alternate’ prompt (at the bottom of Figure 4.1) when an Op Code is selected from the breakdown:

Figure 4.1: Alternate Operations

For further information on garment breakdowns refer to the Garment Breakdown Maintenance on page 18 of this manual. An alternate operation would be used in those cases where an operation (or series of operations) may be done in one path OR they may be done in another, but NEVER would both paths be done. In our example below, we are setting pockets on a shirt using a single needle lockstitch. We also have an automatic pocket set machine, but it does not have the capacity to set all of the pockets in the line. A bundle may go to the automatic machine, or it may go to the manual machine. Which path it will take is not clear at the time the garment breakdown is created.



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Alternate 1 Alternate 2 | | | Crease Pocket Auto Pocket set | | S.N. Pocket Set | | | | If we start the bundle with Crease Pocket, then the coupon on Auto Pocket Set will not be paid (it will be changed to VOID). However, if we start the bundle at Auto Pocket Set, then Crease Pocket and S.N. Pocket Set coupons will be made VOID. The alternate methods will allow the user to include both paths in the labor breakdown, create bundle tickets for both paths, but also insure that only one path will be paid, and only one path will affect your garment cost. It will NOT allow them to create a cascade of alternate paths within an alternate path. It will NOT allow them to place a number or letter in ALT1 AND in ALT2 on the SAME OPERATION. This would not make sense to the system, and therefore should NOT be attempted. In the above example, the primary path will be considered to be the manual method, Crease Pocket and S.N. Pocket Set. In the garment breakdown, we put a ‘1’ into the ALT1 field for BOTH of these operations. This path will be the one that the garment's cost is based on. After these 2 operations are entered, we enter Auto Pocket Set, and put a ‘1’ into the field ALT2. Please note that the numbers or letters used to designate an alternate path MUST MATCH. That is how we identify which operations are associated with each other. This will allow the user to have an unlimited number of operations in either the primary path, or in the alternate path. It will also allow them to have up to 36 different sets of alternates within one garment breakdown (we allow either numbers or letters). So it doesn't matter what is used, as long as ALT1 and ALT2 match. It also doesn't matter if the number of operations in the ALT1 path match the number of operations in the ALT2 path (as our example above illustrates). When a coupon is paid, we check to see if one of the 2 alternate fields has been used. If it is being used, then for that bundle, we mark its matching path as VOID. If an operator turns in a coupon for the other path, it will not be paid! Since this is done on a bundle-by-bundle basis, it will allow the user to start one bundle down path 1, and then start the very next bundle down path 2. Please be aware that if the user resets an operator's earnings, the coupons previously scanned will be marked OK to pay, but, the alternate path which was previously marked VOID cannot be UnVOIDed and so cannot be used. As we stated earlier, the Standard Cost for the garment will be based on the primary path (ALT1). Please keep this in mind when the user is doing the breakdown. However, the Actual Cost will still be based on which coupons are turned in and paid. The printed version of your garment breakdown will show the operations and any alternates used. Initially, the system is not testing that if the user marks an operation in ALT1 that also has a matching mark in another operation in ALT2. However, later versions will be testing when the garment breakdown is entered or modified. So please check the breakdowns carefully by printing them out before actually issuing bundle tickets when the user first starts using alternate paths. Ultimately, it is the users responsibility to make sure that the alternates are being set up correctly.



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If there are any questions regarding the setup of alternate paths, or for any help in correctly creating alternate paths in a garment breakdown, please contact Tech Support



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.

IMPLEMENTATION GUIDE


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APPENDIX C: IMPLEMENTATION GUIDE

Overview The purpose of this section is to provide suggestions and comments about implementing the AS/AP™ Piece Work Payroll system under varying conditions. Since this section approaches the subject from the intellectual angle, there is no attempt to tie into actual menus and screens. Instead, we will discuss such areas as the Rate Book Maintenance and leave it to the reader to determine that the Rate Book Maintenance is accessed through the first selection from the Piece Work Payroll menu. Be careful not to read too much into this write-up. Special care should be taken to place all suggestions and procedures into proper perspective for your particular company. This write-up is based on our knowledge of the AS/AP™ Piece Work Payroll software, our industrial engineering experience, and our accumulated apparel and sewn products experience, but, with limited, and superficial knowledge of individual companies, their current setup, requirements, and problems. What we are trying to say is USE YOUR OWN JUDGEMENT. IT'S YOUR COMPANY AND ULTIMATELY YOUR RESPONSIBILITY TO MAKE THIS WORK.

System Components The AS/AP™ Piece Work Payroll system is built around several basic components. These components integrate and come together in various ways depending on your requirements. The most important thing to remember about the rules is that rules are made to be broken and, that there are numerous ways to perform every job.

Rate Book The RATE BOOK is a list of the operations and corresponding piece rates actively used by your company. In order to identify each operation and rate combination, each must be assigned a unique operation code. Operation Codes can be share from style to style, or they can be unique. Of course, it is a lot easier to maintain a system that shares common operations. For instance, if the pocket setting operation on two garments pays the same rate, on the same equipment and the same operator can perform the job, it is common practice to use the same Operation Code.

Product/Garment Breakdown The Product or Garment Breakdown, also referred to as “routing” is the list of Operation Codes applicable to the construction of a single product in the sequence they are to be performed to assemble the Product/Garment. Because of the unique design of the AS/AP™ Piece Work system, a single code can be used more than one time in the assembly of a single Product/Garment.



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If there are questions about the need for a particular operation, we would recommend placing a VOID ticket at that point in the sequential Breakdown. However, many clients would rather place a valid operation code at that point with a temporary or estimated rate. This decision depends on the particular factory and the relationship with the sewing machine operators.

Piece Work Coupons The coupons are created from the Breakdown combined with the bundle sheet (Cutting Ticket). From the bundle sheet, the system knows the quantity per bundle as well as the style, color, and size, if applicable. The system combines this data by creating an internal record for each operation and bundle increment. If there are 5 operations, and the cutting is made up of 2 bundles with 10 pieces each, the system will create the following records:

Bdl 1 Op 1 10 pcs Bdl 1 Op 2 10 pcs Bdl 1 Op 3 10 pcs Bdl 1 Op 4 10 pcs Bdl 1 Op 5 10 pcs

Bdl 2 Op 1 10 pcs Bdl 2 Op 2 10 pcs Bdl 2 Op 3 10 pcs Bdl 2 Op 4 10 pcs Bdl 2 Op 5 10 pcs

There are 10 coupons printed and recorded internally for piecework purposes. Each bundle ticket (containing 5 coupons) is attached to the appropriate bundle. The individual coupons are then removed from the bundle by the operator performing the job and attached to the operator's work sheet to be turned into the payroll department at the end of the day.

Piece Work Calculation The calculation of the piecework payroll begins with the sewing machine operator turning in the time sheet with coupons attached. The payroll can be manually entered or scanned or a mixture of methods. If the actual bundle and coupon numbers are entered (either manually or through scanning) the coupon can be checked off internally and it's future use or reuse restricted. If the actual coupon number is NOT entered, the system may be able to calculate the pay, BUT CANNOT CHECK OFF, THAT THE COUPON HAS BEEN USED. Most of our clients scan all tickets. A handful of client companies manually enter the coupon number. And several clients total similar operations together and enter the resulting total, which leaves the coupons open in the database. It is VERY important to recognize that the coupons can ONLY be automatically purged from the system if the actual bundle and coupon number is entered (either manually or scanned). Any other method of calculating the payroll will leave the coupons open on the system. When the payroll week is completed and the gross payroll passed to a gross pay system (AS/AP™ Gross-to-Net Payroll, external system such as ADP, or simply cleared from the system) the coupon file is permanently updated. If coupons were individually identified during the calculation procedure, they are



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updated during the weekly update process, archived in the coupon archive file (AAPWARCH), and purged from the Open Coupon file (AAPWOPEN). If the coupons were NOT individually identified, they can only be purged from the system by purging the Cutting Ticket coupons by Cutting Order number. If the user fails to purge completed coupons, they will continue to build up in the file indefinitely.

System Startup The first question is where is your company now? To determine where and how to start, it is important to first document where your company is beginning and what the goals are. In order to assist your company in implementing the AS/AP™ Piece Work system, we have prepared the following sample scenarios.

Startup Piece Work If your company has no piecework system presently and the AS/AP™ Piece Work system is being used to implement piece work in your company, your company is facing more problems then we can resolve here. Our advice, if this hasn’t already been done, is to add a qualified industrial engineer to your staff. DO NOT TAKE THIS WARNING LIGHTLY! A PIECE WORK SYSTEM THAT IS IMPROPERLY IMPLEMENTED AND/OR ADMINISTERED CAN BE WORSE THAN NO PIECE WORK SYSTEM AT ALL. PIECE WORK PAYROLL SYSTEMS ARE NOT A “CURE ALL” FOR INADEQUATE MANAGEMENT. The AS/AP™ Piece Work system is a tool through which your company can administer piecework payroll. To implement the AS/AP™ Piece Work system where no previous system exists, this outline can be followed. But, it is NOT our intent or ability to provide complete detailed instructions on the development of piecework payroll systems. Although coupons can be printed for all WIP, we are STRONG believers in using a more gradual startup. The last option we would ever consider or recommend would be to print coupons from the AS/AP™ Piece Work system to place on ALL of the existing WIPs. That type of approach is costly, easily prone to error, very complex to coordinate, and just plain distasteful for us to even consider. Our recommendation is to pay existing work on a Time Work basis until coupons have spread throughout the sewing floor and the WIP. IN CASE WE WEREN'T COMPLETELY CLEAR IN THE PREVIOUS WARNINGS. IN OUR EXPERT OPINION, A PIECE WORK PAYROLL SYSTEM CANNOT BE STARTED IN A TIME WORK FACTORY BY SIMPLY TELLING THE OPERATOR TO PULL COUPONS FROM THE BUNDLES AS THE WORK IS PERFORMED. THE CHANGEOVER WILL INVOLVE A LONG, TEDIOUS PROCESS OF TRAINING ALLOWANCES AND BONUS PLANS THAT HAVE TO BE DEVELOPED CAREFULLY BY A TRAINED INDIVIDUAL. We recommend the following implementation procedure to startup the AS/AP™ Piece Work system, in an attempt to begin piecework payroll in a facility that is currently based on time work. This procedure indicates the sequence we feel can be taken. The piece rates, training allowances, and bonus plans are an individual matter that has to be determined by YOUR COMPANY. 1 - The recommended method to startup is to pay the operators on a time work basis and while the user enters that data into the AS/AP™ Piece Work system. Since the payroll is now being calculated on the



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NEW system, the user can begin the other steps of the implementation so that coupons can also be printed. 2 - The Rate Book is the basis for the computerized Piece Work system it must be the point to initially focus on to print coupons. Use the Manuals, AS/AP™ Help, and the Demo/Test Company to understand the fields of the Rate Book and their relationships. The key features to consider are the Operation Code, Description, SAM and Rate Levels. It is important to keep in mind that the user ONLY needs the Rates available for the garments they are about to place into work. IT IS NOT NECESSARY TO HAVE EVERY RATE to start processing. 3 - The next (in this case the third) step is to enter the Product / Garment Breakdowns FOR THE STYLES ABOUT TO GO INTO WORK. Although history is great to have, the ONLY Breakdowns that are ABSOLUTELY necessary are the ones about to be entered. NOTHING ELSE REALLY MATTERS! 4 - Check that the NEW ticket layout contains the information your staff needs to function. We think our present layouts are very complete and workable for most, if not, all situations. 5 - The user can now begin printing tickets from the AS/AP™ Piece Work system. The AS/AP™ coupons will begin appearing on the WIP almost immediately. Instruct your company’s sewing supervisors to have the sewing operators group the coupons on the time sheet. This will facilitate manually totaling the pay from the AS/AP™ coupons if necessary. 6 - Since your company is already using the system to calculate the earnings, as coupons appear the operators can begin scanning them without delay. The AS/AP™ Piece Work system allows an unlimited mixture of scanned and manually entered data. Therefore, the computer operator can continue mixing the time work with the scanned data until everything can be scanned. 7 - There are several final considerations:

a. If this system is activated as we have described, there should be NO mixed cuttings. All coupons created on the system should be scanned as they are turned in. b. Since your company will be live instantly, the user must learn the AS/AP™ Piece Work payroll calculation program using the Demo / Test Company. There will be little time to experiment once the scanning of live data begins.

These tests should include entering Operation Codes in the Rate Book, entering a Product/Garment Breakdown, issuing a Cutting Ticket, printing coupons (blank paper will be fine), and finally scanning data to calculate earnings. We know the system works for numerous clients. It is up to your company to determine that it works in the manner expected and need, before proceeding to go live. c. Before rushing into the implementation of the system, it is advisable to determine the best method to use. The AS/AP™ Piece Work system will accept the Operation Code to determine the SAM, or will allow the operator to enter the SAM by itself. If building the history is desired, the user can enter the Style and Cut, but we recommend skipping this in order to simplify the data



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entry process. The quantity and rate can be entered coupon by coupon, or we recommend summing all matching coupons so that the operator enters a single total of the pieces and then either the Operation Code or the SAM. Your company is now running the AS/AP™ Piece Work payroll system. The key to success is to study the plan and use the Demo/Test Company to learn the methods and operation of the AS/AP™ Piece Work system.

Replace Old System Working Properly The first problem is whether the old system is fully functional. Assuming the old system IS working satisfactorily, the user has time to proceed cautiously. The key to success is to not rock the boat. This means that the staff should be prepared for the pending change. We are also STRONG believers in using a gradual conversion. The last option we would ever consider or recommend would be to reprint coupons from the AS/AP™ Piece Work system to replace ALL of the OLD coupons on the WIP. That type of approach is costly, easily prone to error, very complex to coordinate, and just plain distasteful for us to even consider. There may be circumstances under which replacing the OLD WIP coupons is justifiable, but, we cannot imagine one on our own. Therefore, we recommend the following implementation procedure to startup the AS/AP™ Piece Work system, in order to replace a system that is currently functional. 1 - Since the Rate Book is the basis for the entire Piece Work system, it must be the point to initially focus on. Use the Manuals, AS/AP™ Help, and the Demo/Test company to understand the fields of the Rate Book and their relationships. The key features to consider are the Operation Code, Description, SAM and Rate Levels. It is important to keep in mind that Rates are only needed for the garments about to be placed into work. IT IS NOT NECESSARY TO HAVE EVERY RATE to start processing. 2 - The next (second) step is to enter the Product / Garment Breakdowns FOR THE STYLES ABOUT TO GO INTO WORK. Although history is great to have, the ONLY Breakdowns that are ABSOLUTELY necessary are the ones about to be entered. NOTHING ELSE REALLY MATTERS! 3 - Check that the NEW ticket layout contains the information your staff needs to function. This DOES NOT mean to just blindly copy the existing (OLD) coupon. This is your opportunity to improve on the layout, but, be cautious of change just for the sake of change. We think our present layouts are very complete and workable for most, if not, all situations. IF A LAYOUT CHANGE IS NEEDED, be sure to allow enough lead-time. It can take several weeks to modify and test a new Piece Work Ticket (coupon) layout. So, plan ahead. 4 - Here we go! Begin printing tickets from the AS/AP™ Piece Work system at the same time printing tickets from the OLD system STOPS. The NEW AS/AP™ coupons will begin appearing on the WIP



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almost immediately. Instruct your sewing supervisors to have the sewing operators group the NEW coupons on a separate time sheet or together, in a group, on the regular time sheet. This will facilitate manually totaling the pay from the AS/AP™ coupons. 5 - When the operators turn in their time sheets, total them as usual until the NEW coupons begin appearing. As NEW coupons appear, pay them by totaling the number of pieces produced, by Operation Code, and then multiplying by the SAM. Of course, the method of totaling the earnings manually will depend on the capability of the OLD system. AS/AP™ Piece Work system, for instance, will accept the bundle count and Operation Code, and can calculate the earnings from there. So, it is important to study your OLD system and decide which method will work most effectively, keeping in mind that the manual entry will only be used until HALF of the coupons turned in by the operators are NEW. Once at least HALF of the coupons turned in by the sewing machine operators are NEW coupons, it’s time to switch systems. Finish the week with the OLD system down to the Gross payroll. 6 - It is now time to begin calculating Payroll on the AS/AP™ Piece Work system. Simply reverse the process used until now. The computer operator will scan the NEW system coupons and manually enter the OLD coupon data. There are several considerations at this point:

a. The mixed cuttings; the ones that are partially scanned in the NEW system and partially entered through the old system, will have to be canceled in order to close the unused coupons. Therefore, watch these first few Cutting Tickets with a little more care. b. Since your company will be live instantly, the AS/AP™ Piece Work payroll calculation program must be learned using the Demo/Test Company. There will be little time to experiment once scanning the live data begins. These tests should include entering Operation Codes in the Rate Book, entering a Product/Garment Breakdown, issuing a Cutting Ticket, printing coupons (blank paper will be fine), and finally scanning data to calculate earnings. We know the system works for numerous clients. It is up to your company to determine that it works in the manner expected and need, before proceeding to go live. c. Before rushing into the manual entry of coupon earnings from the OLD system, it is advisable to determine the best method to use. The AS/AP™ Piece Work system will accept the Operation Code to determine the SAM, or will allow the operator to enter the SAM by itself. If building a history is desired, enter the Style and Cut, but we recommend skipping this in order to simplify the data entry process. The quantity and rate can be entered coupon by coupon, or we recommend summing all matching coupons so that the operator enters a single total of the pieces and then either the Operation Code or the SAM.

The AS/AP™ Piece Work payroll system should now be running. Eventually the OLD system coupons



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will be completely cleared from your system. The key to success is to study the plan and use the Demo/Test Company to learn the methods and operation of the AS/AP™ Piece Work system.

Replace Manual System We are assuming that the manual system is based on the operator turning in some type of coupon that indicates the quantity produced and the rate (SAM). If there are NO coupons in your present method and a BOOK system is relied upon, the changeover is the same there just aren't any coupons to replace. It is always important to remember, as with other methods of switching systems, the key to success is to not rock the boat. This means that the staff should be prepared for the pending change. If your manual system IS based on coupons, we are also STRONG believers in using a gradual conversion. The last option we would ever consider or recommend would be to reprint coupons from the AS/AP™ Piece Work system to replace ALL of the OLD coupons on the WIP. That type of approach is costly, easily prone to error, very complex to coordinate, and just plain distasteful for us to even consider. There may be circumstances under which replacing the OLD WIP coupons is justifiable, but, we cannot imagine one on our own. We recommend the following implementation procedure to startup the AS/AP™ Piece Work system, in order to replace a system that is currently functional. 1 - Since your company is manual now, it will usually be faster to use AS/AP™ to calculate the manual payroll. The recommended method is to total the bundle (coupon) quantities that have the same SAM and enter the total quantity and SAM as a single line entry. In effect, your company is instantly running the AS/AP™ Piece Work system. Since the payroll is now being calculated on the NEW system, the other steps of the changeover can begin so that coupons can also be printed on the NEW system. Continue to print the coupons using your existing techniques until the following steps are completed. 2 - Since the Rate Book is the basis for the computerized Piece Work system, it must be the point to initially focus on to print coupons. Use the Manuals, AS/AP™ Context Sensitive Help, and the Demo/Test Company to understand the fields of the Rate Book and their relationships. The key features to consider are the Operation Code, Description, SAM and Rate Levels. It is important to keep in mind that the only Rates needed are for the ones for the garments that are about to be placed into work. IT IS NOT NECESSARY TO HAVE EVERY RATE to start processing. 3 - The next (in this case the third) step is to enter the Product/Garment Breakdowns FOR THE STYLES ABOUT TO GO INTO WORK. Although history is great to have, the ONLY Breakdowns that are ABSOLUTELY necessary are the ones about to be entered. NOTHING ELSE REALLY MATTERS! 4 - Check that the NEW ticket layout contains the information your staff needs to function. We think our present layouts are very complete and workable for most, if not, all situations. IF A LAYOUT CHANGE IS NEEDED, be sure to allow enough lead-time. It can take several weeks to modify and test a new Piece Work Ticket (coupon) layout. So, plan ahead.



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5 - Your company can now begin printing tickets from the AS/AP™ Piece Work system at the same time coupons STOP printing, if your company was, using the OLD method. The NEW AS/AP™ coupons will begin appearing on the WIP almost immediately. Instruct your sewing supervisors to have the sewing operators group the NEW coupons on a separate time sheet or together, in a group, on the regular time sheet. This will facilitate manually totaling the pay from the AS/AP™ coupons. 6 - Since your company is already using the NEW system to calculate the earnings, as NEW coupons appear, begin scanning them without delay. The AS/AP™ Piece Work system allows an unlimited mixture of scanned and manually entered data. Therefore, the computer operator can continue mixing the old manual data with the scanned data until everything can be scanned. 7 - There are several considerations at this point:

a. If this system is activated as we have described, there should be NO mixed cuttings. All coupons created on the NEW system should be scanned as they are turned in. b. Since your company will be live instantly, the AS/AP™ Piece Work payroll calculation program must be learned by using the Demo/Test Company. There will be little time to experiment once scanning of live data begins. These tests should include entering Operation Codes in the Rate Book, entering a Product/Garment Breakdown, issuing a Cutting Ticket, printing coupons (blank paper will be fine), and finally scanning data to calculate earnings. We know the system works for numerous clients. It is up to your company to determine that it works in the manner expected and needed, before proceeding to go live. c. Before rushing into the manual entry of coupon earnings from the OLD system, it is advisable to determine the best method to use. The AS/AP™ Piece Work system will accept the Operation Code to determine the SAM, or will allow the operator to enter the SAM by itself. If building a history is desired, the Style and Cut can be entered, but we recommend skipping this in order to simplify the data entry process. The quantity and rate can be entered coupon by coupon, or we recommend summing all matching coupons so that the operator enters a single total of the pieces and then either the Operation Code or the SAM.

Your company is now running the AS/AP™ Piece Work payroll system. Eventually the OLD coupons, if they were being used, will be completely cleared from your WIP. The key to success is to study the plan and use the Demo/Test Company to learn the methods and operation of the AS/AP™ Piece Work system.

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APPENDIX D: PIECE WORK TICKET OPTIONS There are numerous materials available for printing of Piece Work coupons (tickets). The material most widely used by newer clients is the color-coded pressure sensitive labels. Our Standard Labels are 22@ by 3/4". The following coupon layout is our Standard Type P format. This is designed for the 2 1/2" by 3/4" labels and printed on the Okidata 3410 and similar printers (includes the 395 and 591).

HEM SLVS Med 24 1001 000159 A1334 <BARCODE LINE> 001540 7 0.0270 0.65

The above data elements are defined as follows: HEM SLVS - Operation Description [8 characters] Med - Size as designated in the Size Range Table 24 - Quantity in bundle 1001 - Style number - [10 characters] 000159 - Cutting Order Number A1334 - Lot Number <BARCODE LINE> - The actual bar code 001540 - Bundle number 7 - Operation sequence on this bundle 0.0270 - Price ($) per piece 0.65 - Price ($) for the entire bundle In order to setup a system to print these labels System Flag 225 must be set to 5 indicating Okidata (3410/395) . System Flag 190=P is used to indicate the Standard GSC/Barbee coated stock label (2 1/2" by 3/4"). Since the barcoding is built into the printer, it is not necessary to bother with System Flags (219, 220, and 221) that control computer generated barcoding.

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TIME & ATTENDANCE


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APPENDIX E: TIME AND ATTENDANCE Over the years AS/AP™ has interfaced with a variety of time clocks, from various manufacturers. The system relies on ASCII files, exported by the clock system on a daily basis. The following procedure is used to setup AS/AP™ for use with Kronos time clocks: Change Flag 548 = K and reindex the piecework system. It will then be necessary to setup the path and filename for the Kronos clock interface. Using selection <U-4-1-Company-2> will give the user the screen to allow for the entry of the Time Clock Data. A badge number must be entered into each employee file. The badge number should be entered into field #20, which is a five-character field. This field is LEFT JUSTIFIED for any entries that are less than 5 characters. Once these items are complete, the user will be able to import the Kronos clock file into AS/AP™. Since piecework coupons are entered on a daily basis, it will be necessary to import the time clock file before entering the daily coupon information for the piecework operators. The procedure for entering employee’s daily earnings is similar to standard daily pay entry. We are using a block of time and then allocating increments of that time to either on-standard or various off-standard codes where applicable, we then scan in the coupons that are associated with each increment of time. The importing of the clock file is accomplished through a program located at selection <PY-2-8> External Clock Interface (refer to the Gross-to-Net Payroll manual). The same daily entry screen <Y-9-1> used for all piecework payroll entries is used for employees after the clock file has been imported (see page 56 of this manual). The total attendance time (in decimal hours) will automatically appear in the ‘Hours’ field. This field will remain available so that any hour entry can be edited.

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SUPERVISOR BONUS


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APPENDIX F: SUPERVISOR BONUS A program to automatically calculate a bonus for the supervisor in each department is included based on specific client’s activation flags. The following sequence of steps will be required for the bonus to be calculated and placed in the individual supervisor’s Other Pay each week. In the employee file <Y-1-1> for each supervisor, it will be necessary to enter the supervisor=s own employee code in the supervisor block in field #18. There must first be an entry for regular hours for the supervisor before the bonus will calculate. The bonus percentage is based on the weekly department performance, will be shown each regular hour entry for the supervisor. That is why there is a daily calculation under ‘Other Pay’. The bonus will be automatically calculated when the weekly update is run for the piecework payroll, selection <Y-9-C-7>. This calculates the department efficiency and then passes the bonus percentage over the Hourly Payroll. That is why the hourly entries must be completed for the supervisor before running the weekly update. The bonus calculation will also pass through to the ‘Salaried’ payroll if any of the supervisors happen to be paid in this manner, rather than on the Hourly payroll.

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PIECEWORK PROCEDURES


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APPENDIX G: PIECE WORK PROCEDURES To provide a better understanding of the sequence of steps that are normally required to go from the cutting ticket to the warehouse, the following guidelines should be helpful. Add/Edit Cutting Order [F-4-1] The first step is to enter a cutting order. (refer to Finished Goods Inventory manual for further information) Convert Cutting Order to Ticket [F-4-3] The second step is to convert the cutting order. There are two options for this process. (refer to Finished Goods Inventory manual for further information) Convert Cutting Order As Is [F-4-3-1] If the quantity cut is the same as the original order, then use this option. (refer to Finished Goods Inventory manual for further information) Partially Convert Cutting Order [F-4-3-2] If the quantity cut does not match what was scheduled for the original cutting order, then the quantity can be adjusted using this option when converting. (refer to Finished Goods Inventory manual for further information) Split Converted Cutting Order [F-4-3-5] In many cases the situation exists where it is desirable to mix colors and/or styles into a single cut to achieve economies of scale for the cutting room. Yet for the sewing room or bundling requirements, the cut must be segregated differently. For example, a cut for style #1001 has Red, White, Blue with 100 units in each color. Using this selection, Split Converted Cutting Orders, allows the user to separate each color into different Lot Numbers, all with the same Cut Order Number. This allows the user to retain the Cutting Order information while providing the appropriate input for the sewing bundles. In the case of mixing styles, it is essential that different lots be assigned for each style. The piecework system will only allow one garment breakdown to be used for printing tickets. The same results could have been achieved by using the option to Partially Convert Cutting Order [F-4-3-2]. (refer to Finished Goods Inventory manual for further information) After the cutting order has been converted according to its particular requirements, it is now ready to be input into the piecework system. Bundle Sheet Data [Y-8-3] This option is used to break the cut down into sewing bundles. There are two options that can be used for this process. See page 27 of this manual. Automatic - this will take the cutting order and automatically break the bundles down into quantities that have been determined by the default setting in the Style File. For example, if the default bundle size for a style is 60 pieces, then for cut of 500 pieces the program will generate eight bundles of 60 pieces and one bundle of 20 pieces. Bulk - this option allows the user to define the bundle size. For example, a small cut where separation by size or color is desired, and the default bundle size would be too large, then this will allow individual bundle sizes to be entered.



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Assign Numbers & Print Tickets [Y-8-4] This assigns the sequential bundle numbers and gives the option of proceeding with printing the tickets. See page 30 of this manual. Reprint Tickets [Y-8-5] This option provides the user with the ability to reprint either all of the tickets or a selected starting range. This is normally used when there has been a printer malfunction that has resulted in the print job being interrupted. See page 32 of this manual. Place Cut into Work [Y-8-6] If the Work Pool option is active on your system, this requires that a cut be moved into the sewing room WIP by selecting this option. Placing the cut into work makes all of the coupons available for the piecework system and updating for the WIP reporting. Without this function being performed, the user will not be able to scan or enter a coupon into the piecework system. It will be read as an Ainvalid@ ticket. See page 33 of this manual. At this point the tickets are ready to be sent to the sewing floor and the processing of the piecework payroll can begin. The coupons are tracked as WIP until the bundle(s) is/are completed. The last step of the process is moving the units from WIP in the sewing room into the Finished Goods Inventory. This is accomplished by the means of the Inventory Control ticket referred to as the A999" ticket. If the user wishes to use this mechanism, each garment breakdown needs to have, as the last operation listed, the Inventory Control ticket with the operation code of A999". Receipt from Bundle Ticket [F-4-8] This option allows the A999" ticket to be scanned in or manually entered, which will then deduct the units from the WIP and automatically update the Finished Goods inventory. (refer to Finished Goods Inventory manual for further information) Automatic Bundle Breakdown The bundle size of the piecework tickets can be assigned by using a default bundle size that is entered in the style file. Then using selection [Y-8-3-Automatic] for the Automatic bundle breakdown program will allow a cut to have the bundle size default to the quantity that has been predetermined in the style file. For this program to be functional, there are two flags that must be set and a FX program that must be run first. Flag 359 = AY@ Flag 559 = AC@ The default bundle size will be 100 pieces. It will be necessary to then use selection [U-4-4-6] and at the prompt for the program to run enter INVT. (refer to System Utility manual for further information) This program will then activate a field in the style file in which a default bundle size can be established. When editing inventory, item #13 can be used for a default bundle setting. Do not be concerned about the SAM entry as this is not active on your system unless the flag is set for bundle allowances. The setting for flag 559 is the default if there is not an entry in field #13 for a particular style. Otherwise the system will look at the style file first and use the default bundle size established in field #13.



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Index 999 Coupon, 18 ADP

Export (Bridge) Hourly, 72 Alternate Operations, 88, 100 Assigning Numbers, 30 Average Earnings Reports, 61

Add/Edit Payroll Subsidy, 64 Edit Averages, 63 Four-Week, 62 Quarterly, 62 Quick Average Update, 64 Six-Week, 61 System Setup, 64 Thirteen-Week, 63

Base Rate Table, 94 Bi-Weekly

Calculate Payroll, 86 Bundle Count

Adjust, 43 Bundle Maintenance

Functions, 41, 77 Bundle Sheets, 27

Check off List, 36 Spread, 30 Tickets, 36

Bundle Tickets Adjust Bundle Count, 43 Change Inventory Status, 46 Change Operation, 43 Delete Completed, 42 Factory Assignment, 47 Import Exchange Data, 47 Quality Control Adjustments, 46 Scan Unpaid Tickets, 45 Transfer CO, 47 Void a Ticket, 46

Calculate Payroll, 84 Calculate Bi-Weekly Payroll, 86 Calculate Semi-Monthly Payroll, 87 Post Direct Deposit File, 94

Cancelled Tickets Purge, 88

Capacity Planning, 77 Capture Past Data, 80 List Plan Schedule, 79 Modify Plan Schedule, 78 Weekly Report, 77

Capture Past Payroll Data, 80 Checks

Enter Manual, 18 Forms, 98

Codes, 12 use of symbols, 11

Common Operation List Styles, 22

Coupon Register, 68 Coupon Status

Verify, 81 Cutting Incentive, 83 Cutting Incentive Maintenance, 55 Direct Deposit

Post File, 94 Employee

Labels, 27 Lists, 27 Master File, 15 Search, 12

Employee Departments, 96 Employee Maintenance, 15

Employee Master File, 15 Enter Manual Pay Checks, 18 Print Employee Lists and Labels, 27

Enter Hours, 59

Exchange Data Import, 47

Export Payroll to ADP, 76 External Clock Interface, 69 Factory/Plant Assignment, 47 Garment Breakdown, 15, 18, 35

Maintenance, 19 Graphic-WIP

By Cut/Lot, 39 Gross Pay Analysis, 66 Gross Pay Data

Enter Daily, 56 Gross Pay Register, 65 Gross-To-Net Payroll

Update, 76 Implementation Guide, 104 Index Keys

Rebuild, 54 Integrity Test, 96 Interface

INDEX


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External Clock, 69 Inventory Status, 46 Labels

Employee, 27 Labor Requirements

Print, 52 Recalculate, 54

List Employee, 27

Machine Downtime Analysis, 94 Machinery/Group Codes, 93 Maintenance

Employee, 15 Manual Payroll, 18 Material Code Table, 27 Menu

Payroll, 11 Multiple Styles

Change Operation, 24 Delete Operation, 25 Insert Operation, 24

Obsolete Breakdowns Delete, 25

Operation Code Performance, 40

Overtime Automatic, 74 Exception List, 73

Overtime Premium, 56 Pack and Reindex, 26, 87 Payroll

Calculate, 84 Checks, 98 Employee Maintenance, 15 Menu, 11 Running, 12 Stand-Alone, 12

Payroll Data Reset/Delete, 60

Payroll Hours Enter Hours, 59 Export (Bridge) Hourly to ADP, 72 External Clock Interface, 69

Personal Fatique & Delay, 17 PF&D, 17 Piece Work Tickets

Reports, 33 Piecework Indexes

Build, 86 Piecework Procedures, 118 PieceWork Tickets

Reprint, 32 Post

Direct Deposit File, 94 Print

Employee Lists and Labels, 27 Printer

Select, 86 Printer Codes, 84 Printer Control Codes

Install, 84 Printing Tickets, 30 Production Requirements

Reset, 50 Production Summary Report, 69 Rate Basis, 12 Rate Book

Maintenance, 15 Operation, 16 Operations, 34

Raw Material Master Update, 26

SAM, 17 Schedule

Calculate and Print, 51 Schedule Dates

Edit, 50 Schedule File

Edit Requirements, 49 Enter Data, 48 List Requirements, 50

Search Employee, 12

Semi-Monthly Calculate Payroll, 87

Sequencing Overview, 18

Standard Allowed Minutes, 17 Statistical Quality Control, 55 Style Master File Costs

Update, 26 Supervisor Bonus, 116 Symbols, 11 Table

Material Code, 27 Time and Attendance, 114 Training Allowance Chart, 89 Transfer CO to Factory, 47 Update

Raw Material Master, 26 Style Master File, 26

Wages

INDEX


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Export (Bridge) to ADP, 72 Weekly Processing, 72 Week-To-Date Makeup

Recalculate, 73 WIP

Labor Valuation, 41 Schedule and Labor, 52

Work Codes, 12 Work Pool

By Cut/Lot, 40

By Operation, 40 By Style, 39 Summary, 40

Work-In-Process By Cut/Lot, 37 By Operation, 38 By Style, 37 Scheduling, 47 Summary, 39

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