Kanban
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.
Kanban 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 four types of Kanban available in the system trigger
transactions that pull material from different replenishment sources.
1. Inter-Org Transfer – Replenishment through IR ISO
2. Intra-Org – Replenishment through Sub inventory transfer.
3. Production – Replenishment through WIP Job.
4. Supplier – Replenishment through purchase from external
supplier.
Pull Sequence
A 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 make up a
replenishment chain
Pull 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 terms
Planning Only Flag – Program Will Perform
Kanban Calculations. User Can Manually Execute Kanban sequence. User cannot
generate and print Kanban cards or execute the replenishment cycle.
Kanban Size and Number of Kanban Cards – Kanban cards are functionally containers .Kanban
size is number of items in each Kanban container.
Minimum
Order Qty -- This is used when calculating Kanban size or during the
Kanban execution process to aggregate Kanban smaller than the minimum order
quantity. This Field defaults from item master which can be overridden.
Replenishment Lead Time
--This is how long it will take to physically replenish the Kanban.
Production Kanban use the replenishment lead time to
calculate the size of the Kanban but use the Lead Times on the Item Master
window to determine when to schedule jobs created by replenishing the
production Kanban
Supplier and inter-org Kanban use the replenishment lead time
to calculate the size of the Kanban and to schedule the "need date"
for the purchase requisition
Incase Lead Time is Left Blank Kanban will use the lead time
defined in the Item Master window for the "need date" on the requisition.
(Need date = sysdate + pre-processing + processing + post processing time if
the replenishment lead time on the pull sequence is left blank.)
Allocation
Percent -- The allocation percent represents the percent of
independent demand for the Kanban item that is to be supplied from this pull
sequence.
Lot
Multiplier -- When Kanban planning sizes the containers at the
location, it will size in multiples of this quantity ex if Fixed Lot Multiplier
is 10 and Requirement is 15, Kanban Will Generate a card for 20
Safety Stock Days -- Safety
Stock Days is the number of day’s demand that will be added to the Kanban for
safety stock.
Kanban
Chain: Kanban Chain is a series of pull sequences that model the
replenishment network on the shop floor. Example Sub inventory Transfer to
Stores, Stores to Supplier.
Kanban cards are created for an item, sub inventory, and
locator.
Card Status
Kanban cards are generated with a default Card Status of
Active.
If the Supply Status is full, we can temporarily pull a card
out of the replenishment chain by changing the Card Status to Hold.
We can stop the usage of a card by changing the status to
Cancelled Which Cannot be made Active or Hold Again.
A Cancelled Card can be deleted.
Supply Status
All the following Supply Status codes can be set either
manually or automatically.
New --The Kanban has just been created and is not yet
part of the replenishment chain
Empty --The Kanban is empty and a replenishment
signal has been generated (available only for Inter Org and Supplier source
types).
Full -- The Kanban has been replenished.
Wait -- The Kanban is waiting until the minimum order
quantity has been met by the aggregation of cards.
In-Process -- For the Supplier source type, the
purchase order has been approved. For the Inter Org source type, the internal
requisition has been approved.
Non-Replenishable Kanban
Non-replenishable Kanban
are used to meet unexpected peaks in demand. For demand variations that are
infrequent and unplanned, Oracle Flow Manufacturing allows non-replenishable
kanban cards.
These cards are created for specific items in specific quantities
as needed. Non-replenishable kanban cycle through the system only once, after
which they are removed from production.
Points to Note While Creating Manual Kanban Cards
Replenishable and
Non Replenishable KANBAN Cards Can be manually generated.
Replenishable KANBAN
Card Can be Manually Created Only with Reference to Pull Sequence .
Cards can be created
in EMPTY, FULL and NEW Status.
Tables Involved
1. For Pull Sequence --MTL_KANBAN_PULL_SEQUENCES
2. For Kanban Cards -- MTL_KANBAN_CARDS
3. For Kanban Activities -- MTL_KANBAN_CARD_ACTIVITY
Views
2. For Kanban Pull Sequence --MTL_KANBAN_PULL_SEQUENCES_V