Kanban Replenishment
Kanban is a means of supporting pull–based replenishment in manufacturing systems. A Kanban system is a self–regulating pull system that leads to shorter lead times and reduced inventory. Kanban systems are typically applied to items that have relatively constant demand and medium–to–high production volume.
Kanbans represent replenishment signals that are usually manual and highly visible, such as a color–coded card that moves with the material, a light that goes on when replenishment is required, or an empty bin that is moved to the supply location to trigger replenishment.
The system includes an API that can be called by external systems, such as bar code readers, to trigger replenishment signals. Kanbans can be replenished from an external supplier or an internal organization.
The four types of kanbans available in the system trigger transactions that pull material from different replenishment sources.
Inter Org Creates internal requisitions
Intra Org Triggers material movement from a subinventory in the same organization
Production Creates or releases a production job (discrete job, repetitive schedule, or flow schedule)
Supplier Creates a purchase requisition
Kanbans are generally replenishable and cycle through the system from full to empty, remaining active until they are
withdrawn. One–time signals, called non–replenishable kanbans, are used primarily to manage sudden spikes in demand.
On the other hand, the “push” system is a transposition of the “pull’ production system. “Push” is thereby releasing materials into production as customers’ orders are processed and the materials become available. Material Requirement Planning or Manufacturing Resource Planning (MRP) modules are typical “push” systems.
Some may say that Kanban is more of a visual scheduling system. The emphasis here is that Kanban is not a system where everything is put on schedule, it must be made clear that Kanban is a production control system intended to enable the process owner to easily view production requirements and ensure that parts or supplies are ordered/procured only if necessary.
Kanban is generally used in two instructional forms:
1. A simple production instruction (shikake) indicating what, where and when it is needed, and where materials are coming from or going to; and
The purpose of Kanban is, therefore, to automate the inventory controls without the need of analysis or planning.
Status change FAQsQ1: How
Status change FAQs Q1: How does one get the Kanban Supply status to change from Full to Empty after all quantity has been issued out of stores? Ans: Status changes only after the user clicks on Replenish. The Kanban Card status will then change to Empty. Q2: How does one get kanban card Supply status to change from empty to FULL when a discrete job has completed and filled the Kanban? Ans: As Per metalink Bug.2188765 : COMPLETING A PODUCTION KANBAN JOB COMPLETION FORM DOES NOT CHANGE KANBAN STAUS When completing a production kanban job using both Move transaction and Completion transaction, the status of the Kanban card is not getting updated from "In-Process" to "Full".There are no error messages and job is completed successfully. If we use Move transaction screen to complete the job, it completes the job successfully and changes the status from "In-process" to "Full". The problem only occurs when we perform the move transaction first from Move Transaction screen and then go to the WIP Completion screen to perform completion. Tested all possible cases and found out when the card status will remainas "In Process" even after completion . Test case 1 :a) Create Discrete job by replenishing.Go to move transaction form and do easy completion . Here you do not enter any details about the kanban (infact you cannot as there is no field to accept ). Save. You see that card status has changed to FULL . Logic over here is the card number agianst which the completion transactionwas done is defaulted from wip_discrete_jobs. You can see the card number associated to a discrete job by going to discrete job form and clicking on "More". This is very similar to our logic of "should have" completion subinventorydefined if we want to go for easy completion . Test case 2 : a) Create Discrete job by replenishing. go to move transaction . Perform move to To Move of the last step - all quantities. Go to completion tranaction form. Enter job number. Now you can see that you have a field card kanban card number . Enter you card number or choose from LOV. Do the completion transaction . SAve Now you see that card status is changed to "FULL" . It will .check it out. Test Case 3: a) Create Discrete job by replenishing. Go to move transaction form. Perform move to To Move of the last step - all quantities. Go to completion tranaction form. Enter job number. Do not enter any kanban card number. Leave it blank. Do completion transaction. Save. Go and check the card status . It will still show "In Process". This is when you see that card status does not get updated even after completion. Program Logic : When doing completion transaction , program goes by the data in mtl_material_transactions_temp . So i need to enter my card number wheneveri do completion against a card. Entered value goes in MMTT and this willcorrespondingly invoke the inventory routing to update the card statusto FULL .