Kanban

Kanban

• Description
• Safety stock
• Replacement time
• Consumption
• Stock replenishment

Description

A Kanban part is a part for which there is a storage place that is replenished by the employees themselves. The system works like in pharmacies by means of a card (Kanban is Japanese and means "card"), which is located at the bottom of a storage box. If an employee takes the last item from this box, he or she must take the card and pass it on to the purchasing department. There are then so many of these boxes in the Kanban warehouse that the minimum stock level (e.g. a full additional box) is never fallen below). If necessary, production then simply takes these goods without having to create a withdrawal document.

To replenish the boxes, orders or stock orders are created and booked as normal, but in the end no goods are put into storage; the stock level always remains at that of the last inventory.

The provision of production order items or spare parts orders is carried out via the usual staging lists, but no goods storage or goods withdrawals are created from here.
When creating the goods withdrawal documents from the staging lists (staging status and picking list), no document is created, but the item is technically staged (written off from the system as a requirement that is no longer open) and a kanban withdrawal slip is printed immediately.

Safety stock

The safety stock level (SiBe) is determined and entered manually for Kanban parts

Replacement time

The replenishment lead time for Kanban parts is determined via the preliminary parts costing.

Consumption

The funding will be made available as follows

• Level 0 (direct order items)
  • Annexes
    • Call up staging list with job number
    • Selection of items
    • Menu option: WE Create document from selected items
      Here is what happens now:
      • For "normal" stocked parts, goods withdrawal documents are created. These are then printed by the scheduler and taken out of the warehouse by messenger. Then, when the goods have been physically provided, the printed withdrawal documents are returned to the MRP controller, who then posts the goods withdrawal document.
      • No goods issue document is created for Kanban parts, but a Kanban withdrawal list is printed immediately and sent directly to production. The production department uses this list to fetch the material and does not need to return these withdrawal documents to the MRP controller, as no further documents need to be posted.
  • spare parts
    • Picking list is called up via date and selection "spare parts" + option "only without delivery note
    • Selection of items
    • Menu item "Create GR document from selected items" (works exactly as described above for attachments)
• Level > 0 (parts below construction contracts)
  • The kanban withdrawal list is automatically printed out after the production parts list. During printing, the kanban withdrawal is automatically provided technically. This level > 0 items can therefore never be found in picking or staging status lists.

stock management+stock replenishment

For kanban parts, a main inventory is taken annually, which determines the displayed stock level of a part for the entire year. This really means that there are no posted stock movements over the year.
If a card is now handed over to the dispatcher by a production worker, which means that goods must be newly procured for the part indicated on the card, the following scheme applies:

The kanban part is defined by a logistics indicator...

• Order section
  • Create requirement request for warehouse (warehouse requirement)
  • Create order from this
  • Create and print goods receipt. On the accompanying documents it appears that the arrived goods are needed for the Kanban warehouse.
  • Store goods in the Kanban warehouse
  • Post goods receipt document. Now the goods receipt is considered to be put away although there is no goods putaway document. The warehouse stock remains unchanged at the status of the last inventory
• Production part
  • Create stock order
  • Expand parts list
  • Create Gozintographs
  • Create production order
  • Completion of the work sequences of the production order. After completion of the last work sequence, the production order is considered to be finished and the stock order is put into storage. There is no goods putaway document here either. The warehouse stock remains unchanged.

Dispatch account

Kanban parts requirements appear in the MRP account like normal warehouse reservations. However, no balance is calculated down here, as there is no real current stock level.

The groups for stock levels, interim stocks and disposition movements were hidden, as they refer to fixed stock levels and real stock movements and would give a false impression of a current stock level.

Part consumption of Kanban parts can only be determined on the basis of actual order items (level = 0) and part request items (level > 0). For this reason the parts consumption cannot be called up from the MRP account, as this would result in a consumption of 0. This is due to the fact that the parts consumption refers to goods withdrawals, non-stocked production order items and non-stocked goods receipts / direct deliveries. However, these do not exist for Kanban parts.