Kanban

[Former Member]

Dear ,

In our plant we require the shop floor kanban process to be implemented.As i am new to this process kindly explain me the step by step procedure for doing this.

I have seen all the blogs post etc that is mentioned below, but it explains what is the use but never makes sense on the step by step creation and activation.

Here there are various type of kanban like event driven, classic,one card etc.I don't know which to choose the notes are also to elaborate to study.Kindly take me through simple steps and explain me the config as well as the steps for execution to suit my requirment on shop floor kanban.

Any help, sure will be rewarded with points.

Followed link

http://help.sap.com/printdocu/core/Print46c/en/data/pdf/PPKAB/PPKAB.pdf

For Config-

http://help.sap.com/bp_hightechv1600/HighTech_DE/Documentation/H97_Scen_ConfigGuide_EN_DE.doc

Regards,

Deepak GS

[Former Member · Accepted solution]

Hi Deepak,

Kanban is also known as JIT (Just in Time). It works on Pull Principle. i.e. as soon as our bin becomes empty, there should be a trigger to the system for a proposal for system to trigger for its replenishment. For eg if the material is in house manufactured, say in the bin you have kept quantity of 100 pieces, as soon as bin is empty there is trigger for Production Order for quantity 100.

It is simple way of MRP you can say, at one material level. Normal MRP consider all child material etc and explodes BOM.

Main requiremts -

Define Supply Area

Define MRP controller

Define Control Cycle

Define Replenishment strategy

IMPORTANT TCODES FOR 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)

Since you want to use KANBAN WITH MRP so you need to set any active MRP Type i.e. PD etc. instead of ND ( No Planning) in above procedure.

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 through out 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).

Useful links -

http://www.saptechies.com/kanban-mrp/

Regards,
Srini

[Former Member · Accepted solution]

Dear Srini,

Thanks for your step by step reply.

I here i want to implement kanban in shop floor especially from stores to sub assembly.I don't want to disturb the existing master data for those materials means the MRP keys and storage location.We are following MRP exclusively for all the materials in the plant.

Basically i require kanban without MRP in the initial phase let it me manual.Then let me think over of mingling, here we don't have any barcode for scanning it should be manual only.So related to my query what are all the master data corrections needs to be done and kanban steps needs to be followed for generation and status lot etc.

Here i don't want to link this with my production order.Is there a way to handle this separately or linking is must? I don't know kindly suggest.

My requirement is simple i have to follow a kanban from stores material issue in a bin to loading of material in sub assembly line.

Regards,

Deepak GS

[Former Member · Accepted solution]

Yes, Deepak I understand your requirement.

Kanban and MRP are mutually exclusive..that means if material is for Kanban, it will have MRP type ND and will not participate in MRP, only production order trigger will will there whenever bin is empty...

Kanban materials will not be part of MRP and planned as per Kanban cycle.

Hope it is clear.

Regards.

Srini

[Former Member · Accepted solution]

Hi Deepak,

I guess, Your requirement is to Set up simple 'Stock transfers from Main Stores to the Aub-Assembly locations, using Kanban'.

Please use the following process -

Set up two Storage locations in the plant (say MFG1).

SPRO -- Enterprose Structure -- Definition -- Materials Mgt -- Maintain Storage Locations

For example,

• Main Stores        = MS01
• Sub-Assembly   = SA01

Set up a Kanban Strategy for Stock Transfers (say KBST)

• SPRO -- Production – Kanban – Replinishment Strategies – Define Stock Transfer Strategies
  • Enter Plant (MFG1) + Stock Transfer (KBST)
  • Control Type = Stock Transfer with Reservation
  • Movement Type = 311
  • If you are planning to set up Barcode scanning, you can create a PDF form and assign here

Set up a Production Supply Area (Tcode PK05) with the following entries –

• Plant                      = MFG1
• Supply Area        = MFG_SA01
• Storage Location= SA01 (This is the receiving location at Sub-Assembly area)
• Person Responsible = Choose any valid entry

Set up Kanban Control Cycle (Tcode PK01)

• Material               = Enter the Material Number
• Plant                      = MFG1 (enter your plant)
• Supply Area        = MFG_SA01
• Choose the default option ‘ Classic Kanban’
• No. of Kanbans  = 2
• Kanban Qty        = say 5
• Stock transfer    = KBST (enter the strategy configured)
• Storage Location= MS01 (Main Stores from where the goods need to be moved)

This should generate TWO Kanbans.

You can check the Kanban numbers through PK13N or PKMC.  By default, the Kanban status will be ‘Wait’.

Actual Transactions:

• Use Tcode PK21 (or PK13N or PKBC), enter Kanban Id and  Set the status ‘Empty’ – This should create a reservation for stock transfer of the material from Main Stores to the Sub Assembly area
• Use Tcode PK21 (or PK13N or PKBC),  and set the status to ‘Full’ – This should post stock transfer from Main stores to Sub-Assembly with movement type 311

Please check and share your feedback.

By the way, I don't think there is any need for a change in Master data impacting MRP process

Thanks

Senthil

[Former Member · Accepted solution]

Srini,

I am following the process which is stated below :

KANBAN PROCESSES , PROCEDURES AND PRE-REQUISITES

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 through out 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).

I have a problem i have maintained the master data correctly where in process steps point no:6 when the status is changed to empty there is no reservation entry triggered by the system

Kindly help me to resolve where i have gone wrong.

Regards,

Deepak GS

[Former Member · Accepted solution]

Hi Deepak,

Has the Kanban status actually changed to 'Empty'?

Any goods movements posted... like single step Stock transfer?

Can you check the Kanban Strategy for Stock Transfers -

• SPRO -- Production – Kanban – Replinishment Strategies – Define Stock Transfer Strategies
  • Control Type = Stock Transfer with Reservation (& not Direct Stock Transfer)
  • Movement Type = 311

Thanks

Senthil

[Former Member · Accepted solution]

Senthil,

Settings are there for my plant.

Regards,

Deepak GS

[Former Member · Accepted solution]

I have checked the status it is changed to empty only.

The inhouse production statergy is 0001.

It is a new material there is no stock movements posted.

Regards,

Deepak GS

[Former Member · Accepted solution]

Hi Deepak,

Did you actually mean that you use In-house production strategy?

Please note that there are three strategies available in SAP - In house Production, External Procurement and Stock Transfer...

For this requirement, please use the Stock Transfer Strategy...

SPRO -- Production – Kanban – Replinishment Strategies – Define Stock Transfer Strategies

• Enter Plant (ABCD?) + Stock Transfer Strategy(0001?)
• Control Type = Stock Transfer with Reservation
• Movement Type = 311
• If you are planning to set up Barcode scanning, you can create a PDF form and assign here

Thanks

Senthil

[Former Member · Accepted solution]

Hi Senthil,

Thanks for the reply i follow the stock transfer stratergy.

I found where i have done the mistake while creating the control cycle in the inhouse production i have given 0001 [working with kanbans and cost collector]

I have checked the customization for stock transfer it is defined as said by you.

Now the problem is where is the option to make an entry for Stock transfer    = KBST (enter the strategy configured) ? I am able to see only for inhouse in t-code PK01.If i am able to change this then hopefully reservaion and transfer will be created.

Regards,

Deepak GS

[Former Member · Accepted solution]

Hi Deepak,

Please refer to the screenshot below -

Thanks

Senthil

[Former Member · Accepted solution]

Thank you very much senthil.

I have got the reservation triggered for the material.

When i try to do this step: 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).

311 is not happenning from strlocation to str location.Reservation exists for 1000 and RCPT reservation exists for 1001.

Means in master data I have maintained prd storage location as 1001 & EP location as 1000 and in MMSC excluded 1001 location and included 1000 for mrp.The supply area is created for 1001 location.

Correct me if i am wrong in above steps.

Regards,

Deepak GS

[Former Member · Accepted solution]

Hi Deepak,

Has the Kanban status changed from Empty to Full? Or any Error?

Are there enough of stocks in the Main Stores (1000)?

Thanks

Senthil

[Former Member · Accepted solution]

Changed to empty to full there is no errors/

Stock is available.

Regards,

Deepak GS

[Former Member · Accepted solution]

Hi Deepak,

Can you attach the screenshot of the Replenishment Strategy, Supply Area and the Control Cycle?

Regards,

Senthil

[Former Member · Accepted solution]

Hi Senthil,

Thanks you very much i worked it out and corrected.Now the process is found ok. 311 happens and auto stock gets updated in background.

A new query here I have only one supply area where in 2 bins are there how will I be able to identify which is there in raw material store for replenishment and which bin is there in shop floor is there any report for differentiating both bins with respect to storage location.

For example 1000 main stores this is there as empty and 1001 shop floor bin is there and is full or waiting.Is there any reports to check this event.Here I have only container no; 001 , 002 etc.

Thank you very much for the help senthil.

Regards,

Deepak GS

[Former Member · Accepted solution]

Hi Deepak,

Glad that your process works fine now

Reg the identification of bins, Kanban bins at Production Supply Area (actual Shop floor) are supposed to be 'Full' and and once any of the bins gets Empty, it has to be moved to Main Stores for Replenishment.

So, we can presume that the containers with Full/Green status are at Shop floor; and those with Empty/Red status are at Main Stores, awaiting Refill.

The closest option to check/monitor the Kanban status overview would be to transaction PK13N

If your requirement is met, You can mark the useful and correct answers and close the thread.

Regards,

Senthil

[Former Member]

Hello Deepak,

View the belkow link for Master data setting for Kanban:

http://help.sap.com/saphelp_em70/helpdata/en/6d/16104202795b33e10000000a155106/content.htm

http://help.sap.com/saphelp_470/helpdata/en/95/e81fa4f57011d194aa0000e83dcfd4/content.htm

Also there are SDN threads for the same:

http://scn.sap.com/thread/1326817

http://scn.sap.com/thread/1128296

Please go throgh the SDN forum for PP for documents section for more details on the same,Also ensure that you have gone through the related threads for the issue before rising in SDN as I find many threads for Kanban Process configuration.

Hope this helps

Regards