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Kanban Types

1. The document outlines the basic rules and process steps for using kanban in four stock transfer scenarios: 1) from main stores to production, 2) external procurement from vendor to main stores, 3) external procurement from vendor directly to shop floor, and 4) in-house production between sub-assembly and main assembly lines. 2. Key prerequisites include defining backflush indicators, confirmation of production order operations, and maintaining the correct storage locations and MRP types in material masters. 3. The process steps involve creating a supply area, extending materials, adjusting material masters, creating control cycles and schedules, printing/scanning barcodes to trigger stock transfers, and confirming operations.

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Amit Sharma
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30 views5 pages

Kanban Types

1. The document outlines the basic rules and process steps for using kanban in four stock transfer scenarios: 1) from main stores to production, 2) external procurement from vendor to main stores, 3) external procurement from vendor directly to shop floor, and 4) in-house production between sub-assembly and main assembly lines. 2. Key prerequisites include defining backflush indicators, confirmation of production order operations, and maintaining the correct storage locations and MRP types in material masters. 3. The process steps involve creating a supply area, extending materials, adjusting material masters, creating control cycles and schedules, printing/scanning barcodes to trigger stock transfers, and confirming operations.

Uploaded by

Amit Sharma
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as DOCX, PDF, TXT or read online on Scribd
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1.

Stock transfer from Main Stores to Production Line

Basic rules and Prerequisites:

MRP type must remain as it has been like PD or VB or any active MRP type.

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 throughout 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).

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.

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.

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:

MRP type should be ND in MRP1 view of material master.

Availability check should be KP in MRP3 view of material master.

Material received from vendor is directly posted to unrestricted stock.


Inspection at vendors place or vendors process control to ensure rejection
free material. Inspection set up in Material master should be inactive.

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:

MRP type should be ND in MRP1 view of material master.

Availability check should be KP in MRP3 view of material master.


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 throughout 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).

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.

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.

Material received from vendor is directly posted to unrestricted stock.


Inspection at vendors place or vendors 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:

MRP type should be ND in MRP1 view of material master.

Availability check should be KP in MRP3 view of material master.

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 throughout 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).

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.

Maintain KN01 storage location in the field - production storage location of


MRP2 view in the material master.

Maintain Kanban Production schedule profile in Work scheduling view of the


material master.

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 Requirement generation.

(Tcode: PK23)

Goods Receipt India Specific Process

(Tcode: PKBC)

Kanban Board Demand Source view

(Tcode: PK13N)

Kanban Board Supply Source view

(Tcode: PK12N)

Kanban Evaluation

(Tcode: PK18)

Kanban Correction

(Tcode: PK50)

Kanban Locking & Deleting

(Tcode: PKMC)

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