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Kanban Calculation

Hi All,

What is Kanban Calaculation?

When it will be used? How it will be used?

Can any of you guys can please guide me the steps to perform kanban calculation.

What are all dependency factors we need to take care on

Kanban calculation.

Thanks in Advance.

Former Member
Former Member replied


Pls find the details about KANBAN Calculation Automatically as following :

Automatic Kanban Calculation


Significant parameters for production control with KANBAN include:

● The number of kanbans (cards) that circulate in a control cycle

● The quantity per kanban

You use these parameters to define material circulation and material stock. By optimizing these parameters, you can reduce inventory levels to a minimum. The aim is to guarantee material replenishment with the lowest possible inventory. As the inventory situation in many branches of industry fluctuates considerably, it is necessary to check and adjust these parameters on a regular basis.


The following prerequisites exist for the automatic kanban calculation:

You must maintain the standard values for the automatic kanban calculation in the control cycle. For further information see also Defining the Automatic Kanban Calculation in the Control Cycle.

● If necessary, you must maintain the authorization profiles in Customizing for KANBAN (if the dependent requirements are to be smoothed or if you want to maintain work time).

To do so, in Customizing, choose Production ® KANBAN ® Automatic Kanban Calculation and Scheduling ® Define Calculation Profile.

● You must assign the supply areas to the BOM items (either via the production version or by entering the supply area in the material master) as the system only includes dependent requirements that refer to a supply area.

If necessary, you must maintain the detailed dependent requirements selection in the control cycle. For more information, see Control Cycle for Classic Kanban.


The proposals for the number of kanbans or the kanban quantity are calculated on the basis of the results from the planning run or from long-term planning.

The following functions are available in the kanban calculation:

The system determines the relevant dependent requirements (either from long-term planning or from MRP).

The dependent requirements can be smoothed according to the settings in Customizing.

If you have maintained sub-day replenishment lead times in the control cycle and the appropriate work times have been saved in Customizing, the system converts the requirements per day to the time unit of the replenishment lead time. See also: Calculating the Replenishment Lead Time and Converting the Requirements

The system calculates the number of kanbans or the kanban quantity on the basis of a formula.

If the system cannot carry out the calculation, it creates appropriate error messages which you can check in the error log. See also: Accessing the Error Log

Using a special function, you can check the result of the calculation and accept the proposal. See also: Checking and Copying the Automatic Kanban Calculation.



1. First of all you must decide whether you want to carry out the calculation using the data from long-term planning or from MRP.

2. To simplify the maintenance of mass data, you can maintain the calculation profile in Customizing for KANBAN. You must maintain the calculation profile if you want the system to smooth the dependent requirements or if you want to use sub-day replenishment lead times.

3. You must enter the profile or the calculation parameters in the control cycle.

4. Using the report, Change proposal settings for KANBAN control cycles, the system creates proposals for the number of kanbans or the kanban quantity.

5. The proposals are checked and accepted using the function Checking the results of the kanban calculation.

6. You can repeat the kanban calculation as often as necessary so that you can adjust the container circulation to suit your requirements situation.

Defining the Automatic Kanban Calculation in the Control Cycle


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

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

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

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 (for more information on this topic, see also, Smoothing 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 .

Hope this helps.



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