Hi Krishna,
Pls. find the KANBAN Process details 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).
Hope this helps.
Revert if any doubt.
Regards,
Tejas
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