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1、Manufacturing with Kanban Supply into Production (233)SAP Best PracticesPurpose, Benefits, and Key Process StepsPurpose This scope item focuses on different approaches to supply the production using Kanban-controlled business processes.Comprehensive presentation of different Kanban processesBenefits

2、 The replenishment process controls itself and manual posting is reduced as far as possible. Reduction in lead time and stock.Components are not procured before they are needed (just in time). Prevention of overproduction. Reduction of required storage space.Simple and transparent method of organiza

3、tion.Event control and alerting enable timely reaction to changes and issues in the production processKey Process StepsCreation an maintenance of Kanban control cyclesCreating Planned Independent Requirements and Material Requirements Planning (Plant)Classic Kanban: External Procurement with schedul

4、ing agreementsClassic Kanban with JIT calls, calculation and alertingClassic Kanban: In-house production (repetitive manufacturing) with quantity signal and trigger pointClassic Kanban: Stock transfer from warehouse with alertingEvent-driven Kanban with packaging instructions and alertingRepetitive

5、manufacturing backflushRequired SAP Applications and Company RolesRequiredSAP enhancement package 7 for SAP ERP 6.0Company RolesProduction PlannerShop Floor SpecialistWarehouse ClerkPurchaserDetailed Process DescriptionManufacturing with Kanban supply into productionThe scope item Manufacturing with

6、 KANBAN supply into production focuses on a lean production control method within a repetitive manufacturing environment: use of KANBAN processing for lean replenishmentRepetitive Manufacturing is commonly used when a production process meets the following criteria: The same or similar products are

7、produced over a lengthy period of time. The products produced are not manufactured in individually defined lots. Instead, total quantity is produced over a certain period at a certain rate per part-period. The products produced always follow the same sequence through the machines and work centers in

8、 production. Routings tend to be simple and do not vary much.The KANBAN method for controlling production and material flow is based on the actual stock quantity in production. Material that is required on a regular basis is continually provided in small quantities in production. Replenishment or th

9、e production of a material is only triggered when a higher production level actually requires the material. This replenishment is triggered directly in production using previously maintained master data. The entries you have to make in the system are reduced to a minimum. All other actions in the sy

10、stem are carried out automatically in the background.With KANBAN, the production process controls itself and manual posting is reduced as far as possible. The effect of this is a reduction in lead time and in stock.Process Flow DiagramManufacturing with Kanban supply into production (233)PurchaserPr

11、oduction PlannerAdditional ProcessesShopfloor SpecialistOperative MRPReprocessing ListInventory Consumption Standard CostCO-PA =Profitability Analysis, MRP = Material Requirements Planning, GI/GR = Goods Issue/Goods ReceiptEnd ProcessPeriod-End Closing “General” Plant(181)REM Planning TableRepetitiv

12、e Manufacturing BackflushPostprocessing ListGI/GR SlipInventory Receipt Standard CostAgreement in Sales(231)Scheduling Agreement with JIT Inbound(230)Replenish-ment of stock transfer material t is required? Replenish-ment of external procurement material is required? Replenish-ment of rep. manuf. Ma

13、terial is required? Classic Kanban with Scheduling AgreementsClassic Kanban with JIT CallsClassic Kanban:In-house ProductionClassic Kanban: In-house production with quantity signal and trigger pointClassic Kanban:Stock Transfer (Full WM) with AlertingEvent-driven Kanben with packaging instructionsEv

14、ent-driven Kanban : In-house production AlertingClassic Kanban:Stock Transfer (Lean WM)Planned Independent RequirementsProcurement of MaterialsProcess Flow DiagramExternal Procurement using KanbanAdditional ProcessesProduction PlannerWarehouse ClerkGR = Goods ReceiptGoods Receipt PostingGR SlipInven

15、tory Receipt Standard CostScheduling Agreement with JIT Inbound(230)Scheduling Agreements?Check Dependent RequirementsSet Kanban to “EMPTY”Set Kanban to “FULL”JIT Calls?Set Kanban to “EMPTY”Set Kanban to “FULL”Kanban PrecalculationRelease ProposalCheck changes and calculationUnlock KanbansAlertingEv

16、ent-driven/ Packaging Instr.?Create Event-driven KanbanSet Kanban to “FULL”Set Kanban to “EMPTY”Kanban set to “FULL”Process Flow DiagramIn-House Production and Stock Transfer using KanbanProduction PlannerWare-house ClerkConfirm Transfer ORderStock Transfer (Lean WM)?Set Kanban to “EMPTYSet Kanban t

17、o “EMPTY”Set Kanban to “FULL”Stock Transfer (Full WM)?Set Kanban to “IN TRANSIT”Set Kanban to “FULL”AlertingRelease Control CycleIn-house Production with quantity signal and trigger point?Unlock KanbansSet Kanban to “EMPTY”Set Kanban to “FULL”Kanban withdawalIn-house ProductionSet Kanban to “EMPTY”S

18、et Kanban to “FULL”Create even-driven KanbanIn-house Production (Event-driven)?Check Kanban StatusSet Kanban to “IN PROCESS”Set Kanban to “IN TRANSIT”Set Kanban to “FULL”Set Kanban to “EMPTY”LegendSymbolDescriptionUsage CommentsTo next / From last Diagram: Leads to the next / previous page of the Di

19、agramFlow chart continues on the next / previous pageHardcopy / Document: Identifies a printed document, report, or form Does not correspond to a task step in a document; instead, it is used to reflect a document generated by a task step; this shape does not have any outgoing flow linesFinancial Act

20、uals: Indicates a financial posting document Does not correspond to a task step in a document; instead, it is used to reflect a document generated by a task step; this shape does not have any outgoing flow linesBudget Planning: Indicates a budget planning document Does not correspond to a task step

21、in a document; instead, it is used to reflect a document generated by a task step; this shape does not have any outgoing flow linesManual Process: Covers a task that is manually done Does not generally correspond to a task step in a document; instead, it is used to reflect a task that is manually pe

22、rformed, such as unloading a truck in the warehouse, which affects the process flow. Existing Version / Data: This block covers data that feeds in from an external process Does not generally correspond to a task step in a document; instead, this shape reflects data coming from an external source; th

23、is step does not have any ing flow lines System Pass / Fail Decision: This block covers an automatic decision made by the software Does not generally correspond to a task step in the document; instead it is used to reflect an automatic decision by the system that is made after a step has been execut

24、ed. External to SAPBusiness Activity / EventUnit ProcessProcess ReferenceSub-Process ReferenceProcess DecisionDiagram ConnectionHardcopy / DocumentFinancial ActualsBudget PlanningManual ProcessExisting Version / DataSystem Pass/Fail DecisionSymbolDescriptionUsage CommentsBand: Identifies a user role

25、, such as Accounts Payable Clerk or Sales Representative. This band can also identify an organization unit or group, rather than a specific role.The other process flow symbols in this table go into these rows. You have as many rows as required to cover all of the roles in the scope item.Role band co

26、ntains tasks common to that role.External Events: Contains events that start or end the scope item, or influence the course of events in the scope item.Flow line (solid): Line indicates the normal sequence of steps and direction of flow in the scope item.Flow line (dashed): Line indicates flow to infrequently-used or conditional tasks in a scope item. Line can also lead to documents involved in the process flow.Connects two tasks in a scope item process or a non-step eventBusiness Activity / Event: Identifies an action that either leads into or out of the scope item, o