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8/16/2019 Kanban Pull Sequence and Kanban Cards
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Kanban Pull Sequence and Kanban Cards
Kanban
Kanban is a means of supporting pull-based replenishment in manufacturingsystems.
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.
Kanban represent replenishment signals that are usually manual and highlyvisible, such as a color-coded card that moves with the material, a light thatgoes on when replenishment is required, or an empty bin that is moved to
the supply location to trigger replenishment.
The four types of Kanban available in the system trigger transactions that
pull material from different replenishment sources.
1. Inter-rg Transfer ! "eplenishment through I" I#
$. Intra-rg ! "eplenishment through #ub inventory transfer.%. &roduction ! "eplenishment through 'I& (ob.
). #upplier ! "eplenishment through purchase from e*ternal supplier.
Pull SequenceA pull sequence is a group of information that defines a Kanban location,source information, and planning parameters for an item.
An item can have multiple pull sequences that ma+e up a replenishmentchain
&ull sequences are used to calculate the number or quantity in each Kanban
container at that location.
A Kanban location can be a sub inventory or an inventory locator.
Important Pull Sequence termsPlanning Only Flag ! &rogram 'ill &erform Kanban alculations. ser ananually /*ecute Kanban sequence. ser cannot generate and print Kanban
cards or e*ecute the replenishment cycle.
8/16/2019 Kanban Pull Sequence and Kanban Cards
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Kanban Size and Number of Kanban Cards ! Kanban cards arefunctionally containers .Kanban si0e is number of items in each Kanban
container.
Minimum Order Qty -- This is used when calculating Kanban si0e or during
the Kanban e*ecution process to aggregate Kanban smaller than theminimum order quantity. This ield defaults from item master which can be
overridden.
Replenishment Lead ime --This is how long it will ta+e to physically
replenish the Kanban.
&roduction Kanban use the replenishment lead time to calculate the si0e of
the Kanban but use the 2ead Times on the Item aster window to determinewhen to schedule 3obs created by replenishing the production Kanban
#upplier and inter-org Kanban use the replenishment lead time to calculatethe si0e of the Kanban and to schedule the 4need date4 for the purchase
requisition
Incase 2ead Time is 2eft 5lan+ Kanban will use the lead time defined in the
Item aster window for the 4need date4 on the requisition. 67eed date 8sysdate 9 pre-processing 9 processing 9 post processing time if the
replenishment lead time on the pull sequence is left blan+.:
!llo"ation Per"ent -- The allocation percent represents the percent of
independent demand for the Kanban item that is to be supplied from this
pull sequence.
Lot Multiplier -- 'hen Kanban planning si0es the containers at the location,it will si0e in multiples of this quantity e* if i*ed 2ot ultiplier is 1; and
"equirement is 1<, Kanban 'ill =enerate a card for $;
Safety Sto"# $ays -- #afety #toc+ >ays is the number of day?s demand
that will be added to the Kanban for safety stoc+.
Kanban Chain@ Kanban hain is a series of pull sequences that model the
replenishment networ+ on the shop floor. /*ample #ub inventory Transfer to
#tores, #tores to #upplier.
Kanban cards are created for an item, sub inventory, and locator.
Card Status
Kanban cards are generated with a default ard #tatus of Active.
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If the #upply #tatus is full, we can temporarily pull a card out of thereplenishment chain by changing the ard #tatus to old.
'e can stop the usage of a card by changing the status to ancelled 'hichannot be made Active or old Again.
A ancelled ard can be deleted.
Supply Status
All the following #upply #tatus codes can be set either manually orautomatically.
Ne% &&The Kanban has 3ust been created and is not yet part of thereplenishment chain
'mpty &&The Kanban is empty and a replenishment signal has been
generated 6available only for Inter rg and #upplier source types:.
Full && The Kanban has been replenished.
(ait && The Kanban is waiting until the minimum order quantity has beenmet by the aggregation of cards.
)n&Pro"ess && or the #upplier source type, the purchase order has been
approved. or the Inter rg source type, the internal requisition has been
approved.
Non-Replenishable Kanban
7on-replenishable Kanban are used to meet une*pected pea+s in demand.
or demand variations that are infrequent and unplanned, racle lowanufacturing allows non-replenishable +anban cards.
These cards are created for specific items in specific quantities as needed.7on-replenishable +anban cycle through the system only once, after which
they are removed from production.
Points to Note While Creating Manual Kanban Cards
"eplenishable and 7on "eplenishable KA75A7 ards an be manually
generated.
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"eplenishable KA75A7 ard an be anually reated nly with "eference to&ull #equence .
ards can be created in /&TB, 22 and 7/' #tatus.
Tables Inoled
1. or &ull #equence --T2CKA75A7C&22C#/D/7/#
$. or Kanban ards -- T2CKA75A7CA">#%. or Kanban Activities -- T2CKA75A7CA">CATIEITB
!ie"s
1.or Kanban ard --T2CKA75A7CA">#CE$. or Kanban &ull #equence --T2CKA75A7C&22C#/D/7/#CE