DEVELOP AND IMPLEMENT AN INTEGRATED ENTERPRISE INFORMATION SYSTEM FOR A COMPUTER-INTEGRATED APPAREL ENTERPRISE (CIAE) Final Technical Report Research Sponsored by: U.S. Defense Logistics Agency DLA-MMPRT 8725 John J. Kingman Road, Suite 2533 Ft. Belvoir, Virginia 22060-6221 DLA Contract #: SPO100-95-D-1003/0005 Reported by: Dr. Sundaresan Jayaraman Principal Investigator Georgia Tech Project #: E-27-699 rv> Georgia Institute of Technology School of Textile & Fiber Engineering Atlanta, Georgia 30332-0295 Tel: 404/894-2490 Fax: 404/894-8780 E-mail: [email protected] January 1998 SJ-TR-CIAE-9801 "DföTRlärjftGN STATEMENT' Ä Approved for public release; [one QUALITY ussmsmo i Distribution Unlimited Form Approved REPORT DOCUMENTATION PAGE OMB No. 0704-0188 Public reporting burdens for this collection of information is estimated to average 1 hour per response, including the time for reviewing instructions, searching existing data sources, gathering and maintaining the data needed, and reviewing the collection of information. Send comments regarding this burden estimate or any other aspect of this collection of information, including suggestions for reducing the burden to Washington Headquarters Services, Directorate for Information Operations and Reports, 1215 Jefferson Davis Highway, Suite 1204, Arlington VA 2202-4302, and to the Office of Management and Budget, Paperwork Reduction Project (0704-0188), Washington. DC 20503 1. AGENCY USE ONLY (Leave Blank) 2. REPORT DATE 3. REPORT TYPE AND DATES COVERED January 24,1998 Final Project Report: September 14,1996 - November 4,1997 4. TITLE AND SUBTITLE 5. FUNDING NUMBERS Develop and Implement an Integrated Enterprise Information System for a CIAE 6. AUTHORS(S) Sundaresan Jayaraman; Annajee Rao Nott; Rangaswamy Rajamanickam; Lynn Längsten 7. PERFORMING ORGANIZATION NAME(S) AND ADDRESS(ES) 8. PERFORMING ORGANIZATION REPORT NUMBER SJ-TR-CIAE-9801 Georgia Institute of Technology School of Textile & Fiber Engineering Atlanta, Georgia 30332-0295 Through: The Georgia Tech Research Corporation 9. SPONSORING/MONITORING AGENCY NAME(S) AND ADDRESS(ES) 10. SPONSORING/MONITORING AGENCY REPORT NUMBER US Defense Logistics Agency, DLA-MMPRT 8725 John J. Kingman Road, Suite 2533 Ft. Belvoir, Virginia 22060-6221 11. SUPPLEMENTARY NOTES COR: 12a. DISTRIBUTION/AVAILABILITY STATEMENT 12b. DISTRIBUTION CODE Unlimited 13. ABSTRACT (Maximum 200 words) Research has been carried out to design, develop and implement an Information System for defense apparel manufacturers using the building blocks from the Apparel Manufacturing Architecture (AMA), a generic architecture for an apparel enterprise. ARN-AIMS consists of three modules - Order Processing, Order Tracking and Shipping & Invoicing. The Order Processing Module is designed to facilitate the entry of customer orders for stock and special measurements for both military and commercial products. The Order Tracking Module helps the defense apparel manufacturer (DAM) track the status of an order in any part of the enterprise - from order entry through invoicing - and identify bottlenecks in the system. It helps the DAM respond easily to inquiries from the customer (e.g., the Defense Personnel Support Center, DPSC). The Shipping & Invoicing Module generates an invoice (e.g., DD250) based on the order information entered in the system. ARN-AIMS runs on IBM-compatible machines in Microsoft Access for Windows 95. ARN-AIMS has been successfully implemented at three DAM sites. The ensuing benefits to the DAMs have been quantified. The advantages of the architectural approach to information systems development over an ad hoc approach have been assessed quantitatively. 14. SUBJECT TERMS 15. NUMBER OF PAGES Defense Apparel Manufacturing; Enterprise Architecture; Information Architecture; Modeling; Information Systems; Integrated Databases; 72 16. PRICE CODE 17. SECURITY CLASSIFICATION OF REPORT 18. SECURITY CLASSIFICATION OF 19. SECURITY CLASSIFICATION 20. LIMITATION OF ABSTRACT THIS PAGE OF ABSTRACT Unclassified Unclassified Unclassified Unclassified NSN 7540-01-280-550 Standard Form 298 (Rev-2-89) Prescribed by ANSI Std 239-18 298-102 DLA-ARN Short-Term Project Final Report DEVELOP AND IMPLEMENT AN INTEGRATED ENTERPRISE INFORMATION SYSTEM FOR A COMPUTER-INTEGRATED APPAREL ENTERPRISE (CIAE) PPFG-T5-P4, Phase I Contract Number SPO100-95-D-1003 Contractor Georgia Tech Research Corporation Delivery Order # 0005 Delivery Order Title Develop & Implement an Integrated Enterprise Info System for: iCIAE CDRL# A005 CDRL Title Final Technical Report Reporting Period September 16,1996 - November 3,1997 Report Date January 24,1998 Name of PI Dr. Sundaresan Jayaraman E-mail [email protected] Phone 404/894-2490 Fax 404/894-8780 Address School of Textile & Fiber Engineering 801 Ferst Drive, MRDC Suite 3501 Atlanta, Georgia 30332-0295 Georgia Tech Project #: E-27-699 SJ-TR-CIAE-9801 Research Project Personnel Annajee Rao Nott Rangaswamy Rajamanickam Research Investigators Lynn Langston Graduate Research Assistant Sundaresan Jayaraman Principal Investigator Table of Contents Page Acknowledgments ii Executive Summary iii 1. INTRODUCTION 1 2. THE AMA BUILDING BLOCKS 2 3. FEATURES OF THE INFORMATION SYSTEM 3 4. FIELD IMPLEMENTATIONS OF ARN-AIMS 15 5. ARN-AIMS: EVALUATION AND ANALYSIS 17 6. ARN-AIMS AND THE AMA-COMPLIANCE PROCESS 31 7. EDI INTEGRATION 42 8. CONCLUSIONS 50 References 52 Appendix 53 ARN-AIMS User Manual Acknowledgments This research project was funded by the US Defense Logistics Agency under contract number SPO100-95-D-1003. The authors would like to thank Ms. Julie Tsao and Mr. Donald O'Brien of DLA-MMPRT for making this research endeavor possible. The following defense apparel manufacturers also deserve thanks for participating in the implementation of the system developed as part of this research: The New Maryland Clothing Company, DeRossi & Son and Gibraltar Clothing. During the initial stages of the project, researchers from Clemson Apparel Research, an ARN Demo Center, provided input that helped in the development of the system. Their contributions are thankfully acknowledged. The researchers at the Demo Center at CalPoly ATRC deserve thanks for their participation in the implementation of ARN-AIMS in their facility. Finally, Mr. Chandramohan Gopalsamy deserves thanks for his assistance in compiling this report. u Executive Summary ARN-AIMS is an apparel information management system developed as part of Phase I of ARN Project PPFG-T5-P4. Currently, it consists of three modules - Order Processing, Order Tracking and Shipping & Invoicing. The Order Processing Module is designed to facilitate the entry of customer orders for stock and special measurements for both military and commercial products. The Order Tracking Module helps the defense apparel manufacturer (DAM) track the status of an order in any part of the enterprise - from order entry through invoicing ~ and identify bottlenecks in the system. It helps the DAM respond easily to inquiries from the customer (e.g., the Defense Personnel Support Center, DPSC). The Shipping & Invoicing Module generates an invoice (e.g., DD250) based on the order information entered in the system. ARN-AIMS runs on IBM- compatible machines in Microsoft Access for Windows 95. ARN-AIMS has been successfully implemented at three DAM sites: The New Maryland Clothing Company in Baltimore, Maryland, DeRossi & Son in Vineland, New Jersey, and Gibraltar P.R. Clothing in San Lorenzo, Puerto Rico. Prior to the implementation of ARN-AIMS, the Delivery Orders from DPSC were entered and processed either manually or using a spreadsheet. Order Tracking in the enterprise was done manually and there was no formal system in place. The generation of invoices (DD250) was yet another time- consuming and labor-intensive process often requiring the reentry of Contract/Delivery Order information that was originally entered during the Order entry process, leading to errors. The Order Entry/Processing, Order Tracking and Shipping/Invoicing operations were heavily dependent on the one or two individuals associated with those operations. Since the implementation of ARN-AIMS, the Order Entry/Processing time has been reduced from approximately 115 minutes to 30 minutes for a single Delivery Order - a 74% reduction. The time associated with tracking an Order and responding to a single query from DPSC on a Delivery Order has been reduced from approximately 200 minutes to 5 minutes - a 97% reduction. The time for invoicing (preparation and generation of DD250 forms) has been reduced from 140 minutes to 15 minutes - an 89% reduction. The metrics represent a composite view of the timesaving at the three locations. Note: the Order Tracking module has not been implemented at DeRossi & Son. In addition to these tangible savings, ARN-AIMS has reduced the need for duplicate data entry (and associated errors), reduced the amount of manual paper exchange and helped the enterprise organize and enforce a consistent cut scheduling process. In short, ARN-AIMS is enabling the DAM to obtain information "on demand" and use it very effectively for running the enterprise. ARN-AIMS paves the way for realizing an information-integrated supply chain (ESC) in the production and distribution of military clothing items - one of the primary goals of the DLA-ARN Program. in 1. INTRODUCTION A Computer-Integrated Apparel Enterprise (CIAE) is a prerequisite for realizing the vision of customer-driven uniform manufacture (CDUM) for delivering form-fitting uniforms of the right quality in the right quantity at the right price and at the right time to the US Armed Forces. A seamless integration of the various components in the supply or value chain is essential for achieving quick response at the manufacturing end and readiness at the customer end. The primary purpose of this research effort is to design, develop and implement an information management system for Ordering, Tracking and Shipping in a Special Measurement/Quick Response environment based on the building blocks provided by the Apparel Manufacturing Architecture (AMA) [1,2]. The second major objective is to test the AMA Compliance Process being developed as part of the AMA/RICA Maintenance and Enhancement Project. Yet another objective is to explore the integration of the developed Information System with the Automated Order Processing Module (AOPM) being developed by EDI Integration Corp., so that the foundation for the seamless flow of information in order management in a defense apparel manufacturing enterprise will be laid. The developed system will be implemented in a DEMO Center (Clemson Apparel Research) and at the sites of two Defense Apparel Manufacturers (DAMs) - Haas Tailoring and Maryland Clothing. The proposed user friendly system will be extremely useful to DAMs since they currently do not have such information management systems for the targeted functions in the enterprise. In the future, similar modules for other functions (e.g., production planning, scheduling, etc.) will be developed using the AMA building blocks. 2. THE AMA BUILDING BLOCKS The AMA Information model was developed to serve as the database schema for a Computer-Integrated Apparel Enterprise. The model provides a coherent definition of the data maintained by an apparel enterprise [1,3]. The Information model consists of a set of entity-relationship diagrams and a data dictionary. The model is broken up into several functional views, each of which represents a particular aspect of the enterprise operation. These views remain parts of the same model because they share common entity definitions. Each functional view can be spread over multiple diagrams that are connected through page-connectors. The node number and the title of the functional view are printed at the bottom of each diagram [3,4]. The AMA Information model defines the structure of the entities generated and processed by the functions of the apparel manufacturing enterprise and the relationships that exist between these entities. The functional views represented in the model are as follows: 1. Marketing and Product Development 2. Enterprise Support Services 3. Planning and Preparation for Production 4. Production Control 5. Manufacturing 6. Distribution The AMA Information Model spans all the enterprise functions that fall within the defined scope of the architecture. Likewise, the Recruit Induction Center Architecture (RICA) spans all the activities associated with uniform distribution at a Recruit Induction Center (RIC) [5]. 3. FEATURES OF THE INFORMATION SYSTEM The information system is titled ARN-AIMS (Apparel Research Network ~ Apparel /nformation Management System), since it is funded by the Apparel Research Network (ARN) program of the Defense Logistics Agency (DLA). The objective of the ARN is to significantly improve the U.S. apparel industry's ability to meet Department of Defense (DoD) requirements through research, development, and technology transfer for the apparel and related industries, such as distribution, equipment, and materials suppliers. 3.1 ARN-AIMS Development Cycle Figure 3-1 shows the evolution of ARN-AIMS from the basic AMA building blocks to the final product. This figure also illustrates each milestone in the transformation from the AMA building blocks to ARN-AIMS and the associated times. ARN-AIMS Development Development Time (AMA) 1 Analysis of CAR Ordering & Shipping ' ' 1 ManMonth AMA-CAR System 3 ManMonths _L AMA-NMCC System Maryland Clothing Business Practices AMA-NMCC System 1 ManMonth Order .5 ManMonth Tracking .5 ManMonth ARN-AIMS ^5) / \ (DAH) ^JJahMonihs Figure 3-1 ARN-AIMS Development