Glossary of Leadtec Terms
A B C D E F G H I J K L M N O P Q R S T U V W X Y Z
An operation in a style which may be optionally added to the normal sequence of operations is referred to as an Additional Operation. A typical example could be the attachment of a watch pocket on a jean where the same style is used for the jean with and without the pocket. Up to nine levels of Additional Operations may be defined in a style and different levels may be selected for each bundle. Inventory is not tracked at jobs for Additional Operations, but payment for coupons is identical to non-Additional Operations.
The alternate checksum option allows bundle coupons to be printed using an "intelligent" printer that is capable of printing barcodes for a series of sequential bundle numbers and automatically generating the alternate checksum digit. The checksum algorithm used by the printer it is not the same algorithm that the standard system supports. Various system parameters have to be set to use this feature and it assumes that the coupons are printed by other than the realtime system.
Automatic Rotating Shifts
The Automatic Rotating Shift feature allows the set of plant shifts to alternate each week to accommodate different work schedules.
The Automatic Shutdown feature automates the daily startup and shutdown of the real-time programs and the network manager based on a preset schedule defined by the user, performs a back-up of the database, and can be setup to automatically run end-of-day processing.
Average Pay Rate
This is the average value of the operator's piece-rate earnings. It can represent a per hour pay rate for earnings on-standard or straight-time, including selected bonus amounts and/or make-up pay. The average pay rate may be calculated weekly, quarterly, on-demand or weekly on a 13-week rolling historical basis. Also referred to as average, historical average, quarterly average, 13-week average, etc.
This is generally the hourly rate on which the piece-rate of a particular operation is based. It may also be used as guide-lines for payment to operators doing a specific operation or who have a certain longevity with the company. For example, one base rate may be $5.00/hr, another may be $6.00/hr, etc. Most plants use a single base rate. As the base rate increases (generally annually), the "earned" value or "coupon dollars" increase, while the SAH stays constant. The system provides for automatic application of base rate changes to operation and style rates.
One of 3 possible additional excess pay categories that may comprise an operator's earnings. The bonus calculations are selected from a list of options and are specified for use by setting parameters 31-33 for the Windows version and 52-54 on the AS/400. Refer to bonus descriptions.
This is a single coupon representing bulk processing for all of the bundles within a cut. The quantity associated with the bulk coupon is the sum of all bundle quantities. The ability to print bulk coupons is set by parameter #14 Use Bulk Operations.
This is an operation which is performed for all bundles within a cut at the same time. For example, belt loops may be made for all bundles of a cut at one time rather than for each individual bundle in the cut. Bulk operations are specified by placing a "#" character in the Coupon Rate Code field when defining an operation.
The rate at which a bulk operation is paid. In general it would be the sum of the piece-rates for all units completed for the cut for the bulk operation.
The database file which contains a record for each bundle in the system is referred to as the Bundle Control File. The data in each record includes the cut number, style number, bundle quantity and size(s), additional and/or substitute operation indicators, bundle text and the sequence numbers indicating the locations in each section where the bundle may reside. (See Bundle Operation History File.)
Bundle Control Number
A unique 7-digit number assigned to each bundle which has been released into the system. This is the main key (index) into the bundle file for each bundle.
Bundle Operation History File
This file is used to maintain the number of the employee or group that performed each operation on each bundle. The history data is available for display or hard-copy reporting for any bundle until the bundle is physically deleted from the system.
The computed value of the piece-rate, SAM or SAH for the operation multiplied by the quantity in the bundle or by any other multiple that is parametrically selected.
Bundle Rate Changes (Rate Overrides)
Bundle Rate Changes provide a system option that can obtain operator pay rates for jobs performed on a bundle from rates stored in a bundle rate change file rather than from rates stored in the style file. There are two mechanisms for entering override rates for job. The first is by manually entering the override rates using the Bundle Rate Change Maintenance function. This method is generally used when something is wrong with a bundle and the job rate contained in the style does not apply for payment. The other option allows all rates for all jobs to be obtained from the override file. This option is included for those users who have the capability of centrally computing rates for all jobs. As such the computed rates for every job for every bundle are transmitted via the Central Cutting interface as part of the cut download.
Central Cutting (Engineering) Interface
This function is a generic name for the system interface that allows external systems to download engineering data (styles, operations, etc.), cuts (cuts and bundles), bundle rate overrides, manufacturing instructions, and more to the system for automatic processing. Options provide for fixed format files as well as a CSV file layout for cut downloads.
Clock Minutes of Inventory
The Clock Minutes of Inventory function (part of Line Balancing) is intended to show how many minutes of inventory is located at each job or in sum for each job group. The number of minutes is computed by dividing the inventory labor value at each job or job group by the rate at which production is performed.
Continuous Operation Processing (CO)
The Leadtec concept of Continuous Operation (CO) processing is based on the premise that: (a) Operators work continuously during each day and require the real-time system to be active during this work time, and (b) that there is no break-point between shifts to completely terminate one day and start the new day without interfering with use of the real-time system. The CO system allows for operators signing-off late on the last shift of the day, with or without overtime, and signing-on early to the first shift, with or without overtime. It also accounts for production and pay to be distributed to the correct worked day and shift number.
Applies to batch coupons only. This coupon is the last coupon printed for each control section of a style. The information contained on the control may include the section description, text information, style number, cut number, bundle number and the size(s). Control coupons may optionally be printed for sections without operations and blank coupons may be optionally printed following each control coupon.
A collection of operations in ordinal sequence within a style where work cannot be done at more than one operation simultaneously for a bundle. A bundle can and often will exist at more than one job in different control sections at any given time, but can never be at more than one operation within a control section. Each Control Section is identified by a number in the range 1-16 and is described by a Control Section Group Name. Control Section Maintenance used to define each control section.
Control Section Group
A grouping of section names which is used by one or more styles. These are defined in the system text file in records "Cxx000", where the "xx" represents each unique Control Section Group.
Control Section Group Name
A 28-character name assigned to a Control Section Group. It is defined in the text file in records "Cxx000", where the "xx" represents the Control Section Group.
Control Section Name
A 28-character name given to each section in a Section Control Group. The Section Names are specified in text file records "Cxx001" through "Cxx016", respectively, where the "xx" represents each unique Control Section Group. From 1 to 16 controls may exist in a Control Section Group.
Control Section Number
A two digit number in the range 01-16 that uniquely identifies each Control Section in a Control Section Group.
In the realtime system a coupon is used to barcode the bundle number or a to specify a bulk operation to be scanned at each realtime terminal. The individual terminals define the job to access the pay rate so the compons only need to provide the number of the bundle being worked on. In the batch system a coupon represents an operation that is performed on a bundle. There is a coupon printed for each operation for all bundles within a cut (bulk operations excepted). The coupon is printed with enough bar coded information to allow the system to process the payroll and inventory movement for the bundle associated with the coupon.
Coupon Dollars, Coupon Earnings
See Earned Amount
Cut (Cut Number)
Each cut is identified by a 7-character alpha numeric number and is associated with a single style. A cut can contain any number of bundles but the total cut quantity cannot exceed 9999 units. Cuts can be loaded into the system via an interface file referred to as the Central Cutting download or they can be manually entered using the Cut Maintenance function.
Cut Production Status
The Production Status by Cut report and inquiry is basically a variation of the standard Work-in-Process by Cut function. However, this function is designed to show the following information for groups of user-selected cuts and jobs.
- which jobs have been started but not completed,
- which jobs have been completed,
- which jobs are not applicable to a cut,
- how many units remain to be done at those jobs that have been started but not completed,
- how many pieces in total have to be processed through each job whether started or not, and
- how many pieces in total have yet to be processed through jobs that have been started but not completed.
Cut Reassignment Function
The Cut Reassignment Function provides the ability to reassign a cut already in work-in-process to a different style or to a different production line. Reassignment to a different style after a cut is in work-in-process is dependent on both styles having the same controls along with other restrictions. This function is quite useful if (1) there are optional routes through which a cut can pass, and (2) the actual routing is not determined at the time of cutting.
Cut Scheduling Function
The Cut Scheduling function uses the start date of the cut and the defined throughput days for each style and attempts to determine how many units and SAH should be completed for each job for each day. The number of throughput days is the number of days from the start that the first units is expected to be completed through all jobs. The data output includes a comparison of scheduled to actual and a list of cuts in order of their completion ranking.
Overtime may be paid on a daily basis for hours in excess of the shift work time or only on a weekly basis when the total hours worked for a week exceeds the total shift time for a week. Paying overtime (and double time) on a daily basis is a system option.
This generally refers to the task of entering time and coupon data each day for piecework operators when the batch option is used. Data entry may also refer to the task of entering any data via the realtime terminals.
Double time Hours
These are overtime worked hours for which a double time premium is paid rather than a regular overtime premium. The definition of when overtime hours become double time hours is contained in the plant file for each installation.
Double time Premium
The amount of dollars paid for double time hours above the regular time pay for those hours.
Double time Premium Rate
This is the premium rate at which all double time hours are paid. The rate is defined in the plant file for each plant shift.
Earned Amount, Earned Dollars
Similar to SAH, earned dollars is the monetary value of each operation. The monetary value of an operation is the SAH multiplied by the operation's Base Rate (see below). Thus if an operation's SAH is 1.00 and the base rate is $5.00, the operator will have "earned" $5.00. The actual amount that an operator is paid is not necessarily the value that they earned. If they are earning at a rate below their guaranteed rate they must be paid the guaranteed rate. If they earn more, they are generally paid the higher. However, the pay formulas get very complicated and they vary by company.
This is a ratio or percent derived as a measure of operator performance. Efficiency (sometimes called productivity) is calculated as: SAH earned / hours worked. The title heading for the Efficiency (Productivity) calculation may be set by the user in text record "PAREFF", first six characters.
The system provides the following features for emailing utilizing your company's email server: This capability can also be used to send text messages to cell phones if the cell phone carrier provides an email-to-SMS gateway.
- Automatic email distribution of end-of-day and end-of-week reports
- Emailing selected interface files
- Pager messages to notify a system operator of problems from the auto-shutdown
A unique 5-digit number assigned to each employee. Also referred to as clock number.
Extra Pay (also referred to as allowance) generates a supplemental payment to an operator for non-standard conditions without requiring the operator to go off-standard. Typical payments of this type are entered for extra work, re-training, a cut problem, thread changes, etc. An extra pay transaction can be entered manually by a supervisor or be generated by an realtime terminal transaction.
Usually this represents manual data updates to system data files via file maintenance programs. File maintenance is done to modify data which had been automatically calculated or to add information to the system database that could not be added other than manually, e.g. adding new employees, new sections, etc.
A flexible incentive is the earned value for performance of a job which is likely to change based on tasks unique to a specific occurrence of the job. Flexible Incentives are often found when incentives are paid in cutting rooms and distribution centers. For example, an incentive payment for fabric spreading may depend on marker lengths, fabric width, number of fabric rolls, number of "cutouts" for fabric defects, even the type of spreading machinery used. The Flexible Incentives Option provides the ability to compute the rates for these complex incentive payments.
This pay is specified by entering an "F" as the pay rate code using the Labor Code Maintenance function. Once this type is defined the total amount of money to pay for time period is also entered. It is not an hourly rate, but the full payment amount.
Forced Pay Rate
This is a specified hourly rate, such that the operator's pay for the associated time period will be the specified rate (average, guarantee, dollar amount) times the hours worked. The amount paid will not be adjusted upward to minimum if it is less than minimum, nor will it be adjusted upward if the earned coupon value, if any, is greater than the paid amount. The pay rate code indicating this option is an "R" after which "A"verage, "G"uarantee or any dollar rate may be specified.
General Make-up Pay
Make-up pay to operators who are trained as opposed to trainees.
Group Incentive and Group Incentive Terminal
Each operator that clocks in at a group incentive (GI) terminal becomes a member of the group at that point in time. The composition of the group automatically changes as operators clock in and out. As the group works, each bundle is scanned at the GI terminal identical to how it is scanned at an individual realtime terminal. However, at a GI terminal the piecerate of the bundle is divided equally among the operators that compose the group at the time the bundle is scanned. This also applies to the values that drive the motivational timers, i.e., the standard time is divided by the number of operators in the group to derive the target time. Operators may be paid straight piecework, an hourly rate of pay, or a split incentive.
Guarantee Pay Rate
An hourly pay rate assigned to each operator such that earnings must be greater than or equal to the Guarantee Pay Rate times the number of hours worked. It is equal to either the federal minimum wage, plant minimum or any other specified value. Payment of the Guarantee Pay Rate is indicated by a "G" in the pay rate field in data entry. Also referred to as minimum or guarantee.
This refers to the payroll option that produces a gross payroll rather than a net payroll. A gross payroll includes gross dollars earned without taxes or deductions. The output of the gross payroll is usually fed into another off-site payroll system which performs all calculations necessary to produce the actual employee checks and accumulate payroll history.
Historical Accumulator File (HAF)
This optional file allows the system user to store up to 15 different weekly items for each of 13 weeks on a continuous rolling basis. Users may reference this information by displaying, printing or graphing. The HAF Maintenance program provides for the selection of the system variables that are to be tracked for each operator.
If used this defines the job on which an operator is normally assigned. It is specified using the Operator Job Assignments function by setting an "H" in the first position of the user-defined field. Only a single home job can be specified.
An IPR is an individual time segment that is separated by operator and each labor code that an operator works on during the day. The sum of all of an operator's IPRs represents their total output and earnings. The actual pay is adjusted for bonuses, make-up, overtime etc.
Job (Job Number)
A plant location which contains one or more similar machines dedicated to the same operation or group of operations. Jobs (skill centers) are the locations where the system records work-in- process inventory and production. Jobs are defined in the Production/ Inventory (Job) file by a 2-digit line number and a 3-digit number. Line numbers allow jobs to be separately defined for each different production line.
A 30-character description of a Job.
A Job Group provides a higher level of grouping for individual jobs that can be used for functions such as Line Balancing. Any number of jobs, even across production lines, can be assigned to a Job Group using the Job Maintenance function.
A numeric code (0 thru 24) indicating on-standard labor (code=0) or one of the 24 off-standard labor categories (code=01-24). The parametric descriptions for the labor categories are defined using the Labor Code Maintenance function. The data includes the labor code description, the pay rate code and rate type, whether to include the earnings in on-standard efficiency, whether the operator can sign-on using the labor code, etc.
The Line Balancing feature of the system provides extensive information to the supervisors regarding the production progress of the plant against what is expected. The required production can be automatically generated form information provided using the Cut Scheduling function or can be manually specified for each job. The expected production is based on the assignments of each operator and the efficiency that the operator has on the job on which they are working. The line balancing function can also recommend potential operator re-assignments to balance the line.
Lunch Time Exclusion
This amount of time represents the normal lunch period for each plant shift. The system checks each time segment during which an operator performs on-standard and off-standard piecework. The Lunch Time Exclusion is subtracted from the time represented by the segment which starts before the midpoint of the shift lunch period and stops after the midpoint of the shift lunch period.
When an operator goes on the a machine delay labor category it is assumed that a certain amount of time (the machine delay deduction) is to be included in on-standard time before the machine delay time is recorded. Therefore, labor codes defined as Machine Delay require special processing to first remove the Machine Delay Deduction (see below) from the accumulated machine delay time before recording the worked hours to the machine delay labor category. Any number of the 24 off-standard labor codes can be specified as to whether or not their summed time is used to compare against the machine delay deduction.
Machine Delay Deduction
A daily exclusion of the first specified hundredths of hours of any machine delay off-standard time where the number of hours is specified in the plant file for each shift.
The total dollar value required to raise an operator's pay from actual earnings on-standard to the operator's guaranteed pay rate. Make-up Pay is computed daily for daily operator performance reporting. It may be optionally recomputed weekly for weekly reporting and payroll.
Manufacturing Instructions - Realtime
Realtime Manufacturing Instructions provide the ability to display manufacturing instructions (MFIs) to the operator at realtime terminals in response to bundles being scanned or keyed in. These manufacturing instructions may be used at optional levels of detail. For example, the most detailed level of instructions would be to display a separate instruction(s) for each job on each different bundle; less detailed would be displaying separate instructions for each job by cut; less detailed would be instructions for each job by style; and even less detailed would be using the same instructions for an entire bundle, cut or style, regardless of job. A wide range of options is provided and specification of the detail level is a user function. An option also exists to limit the number of times the same MFI is displayed to an operator.
Manufacturing Instructions - Non-Realtime
Non-realtime manufacturing instructions allow the specification of fixed sets of instructions to be printed on coupons based on the manufacturing instruction id specified when a cut is released. The instructions are printed only and are not shown to the operator.
Messaging / Paging
The Messaging feature is designed to enhance the ability of your personnel to respond to critical production situations in a faster and more direct manner. It does this by providing operators, supervisors, mechanics, material handlers, etc. with the tools to send and receive messages directly from their realtime terminal, display stations, pagers and email.
The Modular Manufacturing option is a feature that includes the following software components:
- Pay calculations that support commonly used modular pay schemes to compensate operators. These pay calculations can be configured in many different ways to provide flexible forms compensation.
- Provision for teams to use the realtime terminals to capture time and attendance, track production, and monitor performance and costs.
- A message board display panel that can continuously show the team how well it is performing.
- Flex-time options providing the operators with some flexibility in establishing their work hours.
This refers to the payroll option that produces a net payroll rather than a gross payroll. A net payroll is a complete payroll function performing all calculations necessary to produce the actual employee checks and accumulate payroll history. This system only produces a gross payroll with interfaces to various net payroll systems, e.g., ADP, as well as producing a generic gross payroll interface file that can be used by any net payroll.
The network manager is a PC that controls and concentrates all network traffic between the realtime terminals and the host computer.
A dollar pay amount equal to the amount computed as the greater of: 1) the supervisor's approved rate (i.e. average, guarantee, transfer, split incentive, etc.), or 2) the operators's minimum, multiplied by the actual time spent in the off- standard labor classification. Actual piecework earnings are used if they are greater. If a forced pay rate was specified, the off-standard earnings equal the forced rate times the number of hours, regardless of coupon earnings.
The time a piecework operator works on an operation which is not the operator's normal operation or task. It may also be time spent on the operator's normal operation or task, but which for some reason normal production is not expected.
Time spent by a piece-work operator on the operator's normal job during which normal production is expected.
Operation (Operation Number)
Every task performed in the plant is defined by an operation with an assigned 14 character number before it can be included in the construction of a style. All information associated with each operation is defined with the Operation Maintenance procedure found on the Engineering menu. Basically the list of operations forms the rate structure for the system.
Operation Long Description
A text string of up to 50 characters which describes the operation.
Operation Short Description
If the batch option is used a short operation description is printed on a coupon in 2 sets of 10 characters. The 1st 10 characters of the description is printed over the 2nd 10 characters.
The standard operation types are defined as cutting "C", sewing "S" or finishing "F". These designations are used to separate the rates for each style into the groups by cutting, sewing and finishing, respectively. The standard costs based on these grouping can also be uploaded to BlueCherry if the standard cost BlueCherry interface is used.
Operator Job Assignments
This function is used to specify up to 10 job assignments for each operator specifying the number of hours normally spent on each during a day. The Line Balancing function uses these assignments to automatically compute expected production at the beginning of each day. The function also indicates the labor code on which to place the operator for each assignment as well as a default labor code when the operator signs on to jobs other than those assigned. And this procedure is used to link training curve assignments when the training curve advancement is based on "jobs".
See Guarantee Pay Rate.
See Employee Number.
An Order Number can be entered for each cut to provide a higher level of grouping. Whereas cuts contain bundles, orders group cuts. Many work-in-process functions can provide information by order as well as by cut or style.
Hours worked in excess of the number of hours in a shift on a daily basis or hours worked in excess of the normal hours for a shift on a weekly basis are considered Overtime Hours. The data entry operator has control over the number of Overtime Hours entered as long as they are not greater than the total hours worked.
This is the amount of premium pay paid for the Overtime Hours worked. The premium rate is specified in the plant file for each of 6 possible shifts.
An entity that can be set to any of a number of values such that the operation of the system is altered. The capability to set system parameters allows users to enjoy a wide variety of system functions and the ability to tailor the system to fit unique plant configurations and requirements. Parameters are either stored in the Parameter file and maintained by the Parameter Maintenance function or they are stored in the Text file (see below) and are maintained by the Text Maintenance function.
Parameter File Maintenance
This is the function that allows system users to set and reset many of the parameters used in the system to define optional processing. This function controls the operator selections to insure correctness and functional compatibility.
A factor optionally defined as part of Labor Code Maintenance to act as a multiplier to the piecerate that would normally be computed by the pay rate. Normally it is applied to the pay amount, but it may also be applied earned SAH/SAM, if desired.
A per hour pay amount in dollars. The Pay Rate for each labor category is specified using the Labor Code Maintenance function.
Payroll 4x4 and 4x7
The 4x4 schedule involves doing end-of-week processing every four days where there are two groups of employees working an alternating schedule of 4 days on and 4 days off. The 4x7 schedule involves doing end-of-week processing on a four day cycle and a 7-day cycle where there are two groups of employees working an alternating schedules.
The dollar value placed on each unit of work performed on a given operation.
This is the definition of a single system database. It includes all employees, jobs, operations, styles, etc.
The Plant Maintenance function provides the ability to define all plant-wide parameters including minimum rates and times, days in a week and all shift information.
Worked time which exceeds the specified normal shift time in a day or week. Premium time is paid as overtime and possibly double time.
Premium Time Pay
An incremental pay value for Premium Time arrived at by multiplying the input Premium Time Pay Factor by the actual average earnings for the time period. Premium Time Pay is computed daily if the daily overtime option is set and recomputed on a weekly basis for reporting and payroll.
Premium Time Pay Factor
The factor which is multiplied by the operator's earnings to determine the Premium Time Pay. The Premium Time Pay Factor is either the Overtime Premium Rate or the Double time Premium Rate, respectively. Each of these rates is set in the plant file for each of the possible plant shifts.
Quality, Pay By
The Pay by Quality feature is a special realtime terminal transactions that lets an operator specify the number of units in a bundle that should be paid for up to 5 levels of quality.
A Quit Bundle transaction is done when an operator scans a bundle and wants to record only a portion of the units completed. The system pays the operator for the completed units and allows the same or another operator to complete the remaining units at another time.
In Leadtec terminology "realtime" refers to the processing and response that occurs when an operator scans a bundle coupon, or any other type of card like their employee id, job card, supervisor card, etc. at one of the Leadtec realtime terminals. All necessary processing for that transaction occurs immediately upon receipt by the host system, hence the term "realtime". The operator receives a response back from the host as soon as the host is finished processing the entered transaction, generally within a second or two, depending on the current processing load on the host computer.
The Leadtec realtime terminals are used by each sewing operator to clock in and out, scan bundle coupons, change jobs, request pay and performance information, clock off-standard, and as a "coaching device" to pace themselves and improve their performance. These terminals can also be configured as hourly time clocks (HTC's) to capture time and attendance data for hourly employees, or as Statistical Quality Control (SQC) data entry terminals to capture quality data from inspection operations.
The Leadtec realtime terminal provides a completely interactive dialogue between the operator and the system. Prompts and error messages are provided in clear language (based on each operator's preferred language) and can be modified by the customer.
The terminal consists of a 2-line by 16-character alphanumeric liquid crystal display and a 16-key keypad to respond to system prompts, input low volume data, or input data if a barcode coupon becomes lost or unreadable. An integrated barcode slot reader is used for most data entry, e.g. bundle scans, clock-in, clock-out, and job changes.
RFID (radio-frequency identification) tags can be used on the factory floor to track bundle movement and pay piecerate operators. For the most part the reusable tags take the place of paper barcoded bundle coupons. For the purposes of the shopfloor system each tag is imbedded with a unique number that can be scanned by an RFID scanner. A small scanner is attached to each operator's work station. The scanner reads the tag and uses the number as a key into a database to verify whether the imbedded number matches a valid employee or supervisor or a bundle. The software then performs whatever processing that has associated with the tag, e.g signing an operator in or out for the day, validating a supervisor's passcode, paying the operator for the job, etc.
SAH or SAM
See Standard Allowed Hours.
Section Accumulator File
This file contains a single record for each section in the system. All piecework information processed for each employee within a section is accumulated into the associated section accumulator file record. The data is then used to produce the section performance analysis report, various budget reports and others.
Section Charged / Credited
The charged section is where the cost of labor is charged and accumulated. The Credited section is where the value of production is credited and accumulated.
A unique 3-character code assigned to each section. This code is used as an index into the Section Accumulator file.
The order in which a style is processed through each of the plant stations. Each Sequence represents an operation performed in a style.
A unique 3-digit number associated with the prescribed Sequence of operations for a style. The Sequence Number is used by Leadtec to track inventory on the plant floor and to provide information regarding the operation referenced by the Sequence Number of a Style.
Single Unit Bundle Transaction
The Single Unit Bundle Transaction is designed to allow operators working at jobs that are designated as single unit jobs to receive credit for a single unit each time the bundle coupon is scanned (or manually keyed-in) at a realtime terminal. This mechanism is similar to the way the system works if an operator started a bundle, followed by a "quit" bundle transaction specifying one unit done. The transaction is useful for long cycle time jobs where more than one operator works on the same bundle at a time.
A 5-character field which may be used to identify the size of the garment in each bundle (e.g. 42LRG). A bundle may optionally include a single size or multiple sizes up to 5. However, most Leadtec functions do not recognize multi-size bundles.
A pay rate calculation that may be specified for each labor code which computes a pay rate by the sum of the following optional parts:
(1st factor x Guarantee Pay Rate) +
(2nd factor x Average Pay Rate) +
(3rd factor x Plant Minimum Pay Rate) +
(4th factor x Employee's Base Rate) +
(5th factor x Coupon Value) +
(6th factor x Job Base Rate).
The factors multipliers are stored in text file records "COXxxx", where "xxx" uniquely identifies a each split incentive formula.
Standard Allowed Hours or Minutes (SAH or SAM)
This is the amount of time allowed to perform a given task (e.g., a sewing operation) as determined by engineering. Standard Allowed Hours SAH is the time expressed in hours and Standard Allowed Minutes SAM is the time expressed in minutes. If the SAH or SAM per unit for an operation is divided into the total hours or minutes for a shift, respectively, the number of units considered to be the standard level of production at 100% efficiency will result. Operator efficiency is measured by the following formula: Efficiency = SAH earned / actual time spent.
Operators "earn" SAH's based on the value of an operation. For example, if an operation's engineered value is 1.00 SAH, it should take an operator working at 100% efficiency to complete the job in 1.00 hour. If the operator completes the job in 0.75 hours the operator earns the 1.00 SAH for 0.75 hours of clock time. This would result in an efficiency of 1.00/0.75 or 133%. Conversely, if the operator completed the job in 1.25 hours they would have earned the 1.00 SAH for an efficiency of 1.00/1.25 or 80%.
The only time the SAH value for an operation changes is when the operation parameters are changed, i.e., re-engineered because of a workplace or method change. Formulas for paying operators, i.e., computing gross pay, are often based on efficiency, SAH, earnings, amongst other parameters.
Standard Bundle Quantity
A quantity from 1-999 which is specified for each style as the expected bundle quantity for engineering purposes. A unique bundle quantity is usually input at the time a Bundle Control Number is assigned.
Start/Stop Time Grace Period Exclusion
A particular time period allowance specified for each shift which is applied before the shift start time and after the shift stop time. If a task's actual start time is within the excluded period before the shift start, the actual start time is reset to the shift start time. If a task's stop time is within the excluded period after the shift stop time, the actual stop time is reset to the shift stop time. Hence, actual task start/stop times within these grace periods are reset to the shift's start/stop times.
A particular type of garment which is unique by the operations performed, rates paid for the operations or any other quality which requires a unique representation of the production operations. A Style forms the basis by which Leadtec tracks inventory, computes operator pay and prints coupons. All Styles reside in the system style file where manual maintenance operations allow styles to be added, modified, displayed, listed and deleted.
The 30-character description of a Style.
The system database file in which all styles are maintained. All information regarding a style is located in this file.
A unique 13-character code that serves to identify each style within the system.
An operation within a style that may be used as a substitute for the main style operation. For example, two different pocket stitching operations may be defined in a style. The one may be substituted for the other for any bundles within a released cut. As many as nine levels of Substitute Operations may be specified for a style.
This file contains all text strings used by the system to convert various codes into alpha descriptions for display and report purposes. The file also contains much of the parametric data (not stored in the Parameter File) that is necessary to control many optional functions. Most of the data is static in nature, i.e. it contains little information which is calculated. Information is added to the file, modified and deleted via manual operator file maintenance operations using the Text File Maintenance function and other manual maintenance functions.
Training curves are generally used to modify an operator's pay based on their performance or other criterial over a specified period of time. Training curves are usually employed when an operator is new or is being trained on a new operation. The system contains numerous curve types that can be used and in many cases more than one curve type can be used within the plant at the same time. Curves are maintained by the Training Curve Maintenance function.
Training Make-up Pay
The make-up pay for operators who are designated as "trainees" as opposed to "trained".
A split incentive pay rate when the data entry operator specifies a "T" for the pay rate code. The split incentive factors used for the Transfer Rate formulation of pay is taken from text record "COXT ".
Unit Counter Feature
The Unit Counter Feature is an optional use of the realtime terminal that automatically counts a a specified number of units for each bundle scan instead of processing all units in the bundle. This can be used in situations where multiple people work on the units in a bundle at the same time. The function basically simulates a Quit Bundle transaction when the operator specifies the units done.
Wage Accrual File WAF
The WAF file is the main data storage file for each piecework employee's accumulated payroll and production information. Information is stored for each day for as may weeks as the user specifies. Payroll and all operator performance statistics are taken from the data maintained in this file.