KANBAN for automobile

[Former Member]

Hi

Can anybody help me with KANBAN cycle

i have tried making it , i have succeeded till ctrl cycle and making bins green on gr internal and external both .

But some other functions like creating proposals and with MRP ....not able to understand

I have to show the full sycle external and internal.

Is anybody having clarity on this , can share with me .

Would be of great help

Thanks

Amit

[rupesh_brahmankar3 · Accepted solution]

Hi,

Detailed for each of the above find as below :

KANBAN PROCESSES , PROCEDURES AND PRE-REQUISITES:

1. Stock transfer from Main Stores to Production Line

Basic rules and Prerequisites:

u2022 MRP type must remain as it has been like u201CPDu201D or u201CVBu201D or any active MRP type.

u2022 Backflush indicator is must. It can be defined in the routing or in the material master itself. If Backflush indicator is set in the material master, then the material will be backflushed through out the plant (Material issue not required against production order). However if you want the material to be backflushed only when it is used for certain products, then Backflush indicator should be set in the routing ( in the component allocation against operations).

u2022 Confirmation should be done for each operation in the production order either individually (CO11n) or collectively (CO15). Confirmation posts goods issue of components (relevant to confirmed operation/s) to production order

u2022 Maintain KN01 storage location in the field in Production Storage Location of MRP2 view in the material master. Back flushing will take place from this location. Field - Storage location for external procurement (EP) should be MN01 (Main Stores) in the material master.

u2022 KN01 - Kanban Storage Location stock is excluded from MRP.

Process steps:

1. Create supply area for Kanban storage location (KN01). TC: PK05

2. Extend the material to Kanban storage location. TC: MMSC

3. Make the necessary changes in the material master as explained above.

4. Create Kanban control cycle. TC:PKMC

5. Print the barcode. TC:PK17

6. Set the kanban status to EMPTY by scanning the barcode. TC: PKBC. A material reservation will be created for stock transfer from main stores to KN01.

7. View the demand source view. TC: PK13n

8. Once the Main stores sends the material to shop floor scan the barcode to FULL. TC: PKBC (At the background stock transfer with 311 movement will happen).

2. External procurement from Vendor to Main Stores

Basic rules and Prerequisites:

u2022 MRP type should be u2018NDu2019 in MRP1 view of material master.

u2022 Availability check should be u201CKPu201D in MRP3 view of material master.

u2022 Material received from vendor is directly posted to unrestricted stock. Inspection at vendors place or vendoru2019s process control to ensure rejection free material. Inspection set up in Material master should be inactive.

u2022 Backflush is not required and Material is issued against a Pick List for Production Order.

Process steps:

1. Create supply area for Main stores. TC: PK05

2. If required, extend the material to main storage location. TC: MMSC

3. Make the necessary changes in the material master as explained above.

4. Create scheduling agreement. Put kanban indicator (X) in the additional data of item.

5. Create Kanban control cycle. TC:PKMC

6. Print the barcode. TC:PK17

7. Set the kanban status to EMPTY by scanning the barcode. TC: PKBC. A Schedule line will be generated for the supply of material to main stores.

8. View the demand source view. TC: PK13n

9. When the material is received at Gate, perform goods receipt into blocked stock (movement type 103). TC: MIGO

10. Once the material reaches Main stores scan the barcode to FULL. TC: PKBC (At the background GR with 105 movement will happen).

3. External procurement from Vendor directly to shop

Basic rules and Prerequisites:

u2022 MRP type should be u2018NDu2019 in MRP1 view of material master.

u2022 Availability check should be u201CKPu201D in MRP3 view of material master.

u2022 Backflush indicator is must. It can be defined in the routing or in the material master itself. If Backflush indicator is set in the material master, then the material will be backflushed through out the plant (Material issue not required against production order). However if you want the material to be backflushed only when it is used for certain products, then Backflush indicator should be set in the routing ( in the component allocation against operations).

u2022 Confirmation should be done for each operation in the production order either individually (CO11n) or collectively (CO15). Confirmation posts goods issue of components (relevant to confirmed operation/s) to production order

u2022 Maintain KN01 storage location in the field - production storage location of MRP2 view in the material master. Back flushing will take place from this location. Field - Storage location for external procurement should be KN01 in the material master.

u2022 Material received from vendor is directly posted to unrestricted stock. Inspection at vendors place or vendoru2019s process control to ensure rejection free material. Inspection set up in Material master should be inactive.

Process steps:

1. Create supply area for kanban stores (KN01). TC: PK05

2. Extend the material to Kanban storage location. TC: MMSC

3. Make the necessary changes in the material master as explained above.

4. Create scheduling agreement. Put kanban indicator (X) in the additional data of item.

5. Create Kanban control cycle. TC:PKMC

6. Print the barcode. TC:PK17

7. Set the kanban status to EMPTY by scanning the barcode. TC: PKBC. A Schedule line will be generated for the supply of material to kanban store.

8. View the demand source view. TC: PK13n

9. When the material is received at Gate, perform goods receipt into blocked stock (movement type 103). TC: MIGO

10. Once the material reaches shop, scan the barcode to FULL. TC: PKBC (At the background GR with 105 movement will happen).

4. In house production (Between one sub-assembly line to Main assembly)

Basic rules and Prerequisites:

u2022 MRP type should be u2018NDu2019 in MRP1 view of material master.

u2022 Availability check should be u201CKPu201D in MRP3 view of material master.

u2022 Backflush indicator is must. It can be defined in the routing or in the material master itself. If Backflush indicator is set in the material master, then the material will be backflushed through out the plant (Material issue not required against production order). However if you want the material to be backflushed only when it is used for certain products, then Backflush indicator should be set in the routing ( in the component allocation against operations).

u2022 Confirmation should be done for each operation in the production order either individually (CO11n) or collectively (CO15). Confirmation posts goods issue of components (relevant to confirmed operation/s) to production order

u2022 Maintain KN01 storage location in the field - production storage location of MRP2 view in the material master.

u2022 Maintain u2018Kanban Production schedule profileu2019 in Work scheduling view of the material master.

u2022 Material should have a valid BOM & Routing.

Process steps:

1. Create supply area for Kanban store (KN01). TC: PK05

2. Extend the material to Kanban storage location. TC: MMSC

3. Make the necessary changes in the material master as explained above.

4. Create Kanban control cycle. TC:PKMC

5. Print the barcode. TC:PK17

6. Set the kanban status to EMPTY by scanning the barcode. TC: PKBC. A production order will be generated (with release status).

7. View the demand source view. TC: PK13n

8. Confirm the operations. TC:CO11n / CO15

9. After the confirmation of last operation, scan the barcode to FULL. TC: PKBC (At the background GR with 101 movement will happen).

Tcodes used in KANBAN:

Create Supply Area

(Tcode: PK05)

Create Control Cycle

(Tcode: PKMC)

Kanban Transaction through Scanning or

Manual operation.

(Tcode: PKBC)

Event Driven Kanban u2013 Requirement generation.

(Tcode: PK23)

Goods Receipt u2013 India Specific Process

(Tcode: PKBC)

Kanban Board u2013 Demand Source view

(Tcode: PK13N)

Kanban Board u2013 Supply Source view

(Tcode: PK12N)

Kanban Evaluation

(Tcode: PK18)

Kanban Correction

(Tcode: PK50)

Kanban Locking & Deleting

(Tcode: PKMC)

Hope will work for you.

Regards,

R.Brahmankar

[Former Member · Accepted solution]

Hi Brahmankar

Thanks a lot for your detailed explaination

I have also achieved to some extent but some questions remain unanswered :

1. Automatic kanban calculation

2. Barcode will be single or multiple would be printed

3. Suppose i have given the barcodes for supplying to my vendor then how would i be clear that which all i have given so that i may not give same again , i mean repetitive printout.

4. I have seen in error processing forcible also kanban can be made empty / full

and how can be integrate with MRP

May be asking many details but actually i cudnt find clear answer to all these issues

Thanks

Amit

[Former Member · Accepted solution]

How time phased planning is used ??

[rupesh_brahmankar3 · Accepted solution]

Dear,

You need to have the Planning Calender created and assigned in the MRP-2 View apart from your Lot-sizing procedure.

If you selected the "time-phased planning" MRP type, the planning calendar that you specify here defines the delivery cycle. This specifies the days on which the vendor delivers the material. You can enter the planning cycle in addition to the delivery cycle.

The following example refers to the use in connection with the "time-phased planning" MRP type.

Hope it will help you.

Regards,

R.Brahmankar

[Former Member · Accepted solution]

Hi,

1. Defining the Automatic Kanban Calculation in the Control Cycle

Purpose

You can also use the functions available in the automatic kanban calculation to determine the number of kanbans or the kanban quantity.

This process describes which parameters you must set in the control cycle so that the system can calculate kanban circulation itself.

Process Flow

1.You set the calculation type. This controls whether the number of kanbans or the kanban quantity is to be calculated.

2.You set the safety factor. This is used to buffer requirement fluctuations. It is multiplied by the result of the kanban calculation formula.

3.You set the constant. Using the constant, you can control the signal for reporting a kanban empty as follows:

If a kanban is reported empty when the kanban is completely empty, the constant is set to u20181u2019. If several work centers of the same supply area report empty kanbans in this way, this constant is multiplied by this number of work centers.

If, on the other hand, the kanban is reported empty as soon as the first part is withdrawn, you set this constant to u20180u2019.

You can also use this constant to plan a safety stock.

You set the calculation type. You define the calculation profile in Customizing for KANBAN. This profile simplifies the maintenance of the calculation profile as it contains the parameters mentioned above as well as the smoothing procedure for the dependent requirements and if necessary a distribution function for smoothing.

You set the replenishment lead time. You can enter this time in days or in hours and minutes.

For the kanban calculation, the dependent requirements planned in the supply area in which the material is required have to be calculated. Here, the system uses the supply area from the dependent requirements. To determine the supply area in dependent requirements read the section Storage Location and Supply Area Determination in the BOM Explosion) .

If, in special cases, the supply source determination is not possible or desired for a dependent requirement, you can use the function Detailed dependent requirements selection to define any combination of plant, storage location and supply area. Here, the system then includes all dependent requirements that apply to your selection criteria in the calculation of the control cycle. The following examples are possible:

If, for a material in a particular plant, you have only maintained one control cycle and if all dependent requirements in this plant are to be included in the calculation of the control cycle, then you do not have to use the storage location/supply area determination function. Instead, you only need to enter the plant in the detailed dependent requirements selection. Then, the system includes all the dependent requirements in this plant in the calculation irrespective of the storage locations or supply areas to which these dependent requirements belong.

If a control cycle supplies material to a buffer store which supplies material to other control cycles, dependent requirements only exist in the system for the second type of control cycle. To calculate the control cycle for replenishing the buffer store, you can assign all the other supply areas that draw material from this buffer store using the function detailed dependent requirements selection. This means, the appropriate dependent requirements are included in the calculation of the buffer control cycle.

When entering the detailed dependent requirements selections, note the following: if instead of entering the complete combination of plant, storage location and supply area, you only enter the plant and storage location, for example, the system reads all dependent requirements in the plant and storage location irrespective of the supply area recorded in the dependent requirements. The same also happens if you only enter the plant. Here, the system uses all dependent requirements in the plant irrespective of the storage location and the supply area.

To access the detailed dependent requirements selection, choose Goto ® Dependent reqmts selection. The dialog box, "Detailed Dependent Requirements Selection" appears where you can make your entries.

You carry out the calculation and evaluation or copy using the function Automatic Kanban Calculation .

2. Barcode printing will be for two mandatory statuses : Empty & Full.

Hope this helps.

Regards,

Tejas

[artem_illarionov]

How I can ban possibilities post GR to Kanban which already in status “FULL” ?