Kanban setup, label layout, and order generation

The kanban supply system is applicable if:

  • Parts usage by assembly order is not exactly known (nuts, bolts, grease, oil, and so on).
  • Exact inventory administration is not possible for the shop floor warehouse.
  • Inventory records for parts are not maintained for the shop floor warehouse.

The items are supplied from a business partner, work center or warehouse to a shop floor warehouse. Typically, these items are defined as floor stock items, and the warehouses as shop floor warehouse, but Kanban also allows non-floor stock items and normal warehouses.

Setup

The following steps are optional:

  1. To define a warehouse as a shop floor warehouse, select Shop Floor in the Warehouse Type field of the Warehouses (whwmd2500m000) session.
  2. To define an item as a floor stock item, in the Items - Warehousing (whwmd4100s000) session, select the Floor Stock check box.

To enable the supply to a warehouse of the Shop Floor type using the kanban supply system, in the Warehouse - Item (whwmd2110s000) session, define the following master data:

  1. Supply System: KANBAN.
  2. If supply must take place from a warehouse, the Supply-from Warehouse check box must be selected and the Supply Warehouse can be specified.
  3. If supply must take place from a supplier or a work center, the Supply-from Warehouse check box must be cleared. Whether the supply takes place from a work center or a supplier depends on the item type:
    • If the item type is Purchased, supply must take place from a supplier. A buy-from business partner and a ship-from business partner can be specified from which the supply must take place. If no buy-from business partner and ship-from business partner are specified, LN retrieves the item's default supplier from the Item - Purchase Business Partner (tdipu0110m000) session.
    • If the item type is Manufactured, supply must take place from a work center. LN retrieves the work center from the Shop Floor Control module in Manufacturing.
  4. Number of Kanbans
    The number of bins that is used to supply the assembly line or production line.
  5. Supply Quantity
    The default quantity that must be supplied in a bin.
  6. Label Layout
    The code of the layout that is used to print labels for kanban.
  7. Kanban ID
    The identification number of the bin. To generate the kanban ID, choose Generate.
Kanban label layout and printing

To create and maintain label layouts for labels to be used for kanban, use the Label Layouts (whwmd5520m000) session.

To print the labels, use the Print Labels for Kanban (whwmd5422m000) session.

To be able to generate a kanban ID in the Warehouse - Item (whwmd2110s000) session, first the default Kanban ID Mask must be specified in the Master Data Parameters (whwmd0100s000) session.

Order generation

During production, a kanban supply order must be created manually. You must visually verify that the bin is empty and should be replenished. The replenishment is started by means of Generate Orders (KANBAN) (whinh2200m000) session, which can be activated from the appropriate menu in the Warehousing Orders (whinh2100m000) session. When the Generate Orders (KANBAN) (whinh2200m000) session is started you only need to either scan or manually enter the label attached to the bin, or enter the item and warehouse and choose Generate. You can change the default values before you choose Generate.

In the Generate Orders (KANBAN) (whinh2200m000) session you can use the Process Transfer Orders check box to specify whether the created order must be processed directly. If the check box is selected, the automatic activities of the outbound and inbound procedures that are linked to the warehousing-order type, are executed immediately. To enable LN to carry out the procedure automatically, you must define a warehousing-order type with only the outbound procedure containing the Generate Outbound Advice (whinh4201m000) step, and the other procedures empty. Because automatic print steps in the shipment procedure do not stop the direct processing, they may also be included.

The following types of kanban orders can be generated:

  • Warehousing orders of type Transfer, if supply must take place from a warehouse. You can view the generated warehousing orders in the Warehousing Orders (whinh2100m000) session.
  • Purchase orders, if supply must take place from a business partner. You can view the generated purchase orders in the Purchase Orders - Overview (tdpur4500m500) session.
  • Production orders ( SFC), if supply must take place from a work center. You can view these generated production orders in the Production Orders (tisfc0501m000) session.
Note

Planned inventory transactions that are excluded from planning, that is, for which the Exclude from Planning have quantity 1, are not taken into account for KANBAN runs.

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