BSD Live Chat Support
Knowledgebase
Kanban master maintenance
Posted by on 15 February 2014 12:41 PM

Purpose

Kanban Master Maintenance is used to set up kanban loops, which are workflows that control inventory traffic between a supplying source and a consuming destination. The loop supplies a kanban supermarket, which is an inventory location that can hold either finished goods or WIP materials that supply another kanban loops. Loops receive input from a manufacturing process, an external supplier, or an inventory supermarket supplied by another loop.

Method

Item: Enter kanban item number

SM Site: Enter Supermarket Site

Supermarket: Enter Supermarket

Step: Enter Process Step

Press Enter or click on next to continue

Source Type: Enter Source type, this can be Process, Inventory or Supplier

Press enter or click on next to continue

 

Source Site: Enter the site code associated with the process or inventory supermarket that supplies this loop. This field does not display when source type is supplier

Process ID: Enter a process defined in Kanban Process Maintenance as either a pacemaker or a standard process. This field displays only when source type is process

Use FIFO: Enter Yes to display an additional frame that lets you enter one or more references to FIFO( lane processes used to produce this kanban item.

Supermarket: Enter a supermarket defined in Supermarket Maintenance that supplies this kanban loop. This field displays only when Source type is Inventory

Supplier: enter a valid, active supplier code defined in Supplier Create. This field only displays when Source type is Supplier

Purchase Order and Line: Optionally, identify the purchase order used to obtain this kanban item from the supplier. This field only displays when Source Type is Supplier.

Press enter or click on next to continue

 When use FIFO is set to Yes, the above screen will appear.

Seq: Enter the sequence in which material goes through FIFO lanes during this process

Press enter or click on next to continue

Process: enter a valid FIFO process ID

Press enter or click on next to save the data

Click on back to continue

Order Point: Optionally specify the supermarket inventory level at which a replenishment order is signaled to the supplying process.

Count Tolerance: Specify the allowable % of variation between the kanban inventory or WIP quantity, calculated as the number of full kanbans times the kanban quantity and the system inventory balance, adjusted by the quantity represented by the lag factor. The default is 5%.

Lag Factor: Specify the number of kanbans that are expected to be in process at any particular time. The default is 0.

Buffer Maximum: Optionally, specify the maximum quantity of the item to be maintained in inventory at this supermarket.

Buffer Modified: the system indicates whether the initial buffer size has been updated.

Limit Display: indicate how the values in the Critical Limit and Warning Limit fields are specified.

Critical Limit: Specify the % of the Buffer Maximum value of quantity of items the system should use in determining whether the supermarket buffer size is too small.

Warning Limit: Specify the % of the Buffer Maximum value or quantity of items the system should use in determining whether the supermarket buffer size is too large.

Daily Demand: Optionally enter the expected daily demand for the item supplied by this kanban loop

Average Demand Template: Optionally, specify the template used to calculate the value in Daily Demand when you run Average Demand Calculation or update demand using the kanban workbenches

Variability: enter the variability factor for this item. This value is used in order point and order quantity calculations

Demand Modified: The system indicates whether the value of Daily Demand has been updated from its initial setting

Demand %: If the supplying source for this loop provides the same item to more than one supermarket, enter the % of that source’s total demand consumed by this supermarket.

Average Inv Calc Method: Specify the average inventory calculation method for this loop

Pack Quantity: Specify the number of items that are included in the standard packaging for this item.

Package Type: Optionally, specify the type of packaging that holds the quantity shown in Pack Quantity.

Press enter or click on next to continue

Safety Stock: Optionally, enter the quantity that is maintained at the supermarket as a buffer to offset unanticipated fluctuations in supply or demand, such as material shortages or special customer orders.

Safety Stock Template: Optionally, specify the template used to calculate safety stock when you run Safety Stock Calculation or update safty stock using the kanban workbenches.

Safety Days: enter the number of days of demand to be covered by safety stock quantity.

Safety Stock Method: Specify the method used to determine safety stock for this item when you run a program that updates safety stock

  • Manual – no safety stock calculation takes place
  • Simple – the system calculates a standard deviation of average demand over the number of days in the planning horizon
  • Peak – the system calculates the average demand for each n-day period within the planning horizon defined in Demand Calculation Template Maintenance, where n is the value specified in Peak Average Days.

Service Level: enter a service level Associated with this item for this kanban loop.

Peak Average Days: When Safety Stock Method is Peak, enter the number of days the system should use a  basis for determining peak average demand.

Supermarket Fax: Optionally, enter a fax number for the supermarket supplied by this kanban loop.

Supermarket Fax 2: Optionally, enter a further fax number for the supermarket supplied by this kanban loop.

E-Mail: Optionally, enter an e-mail address for the supermarket supplied by this kanban loop.

One/Two Card: Enter either One of Two to indicate the number of card printed per container.

Kanban Planner: Optionally, enter the code for the planner who is responsible for this kanban loop.

Press enter or click on next to continue

Order Quantity: Enter the number of units the supplying source will replenish when the inventory level at the supermarket reaches the order point.

Number of Cards: Enter the number of cards to be included in this kanban loop.

Kanban Quantity: Enter the number of items per Kanban

Container Capacity: This field identifies a physical constraint placed on the container or item, which could be any of the following:

  • Maximum quantity held by a carton or container
  • Standard supplier package size
  • Production constraint such as sixe of an over tray
  • For unwieldy or heavy items, the maximum amount that can be handled

Container Type: Optionally, enter the type of container associated with this kanban item when it is replenished, such as bin or carton

Print Quantity: Enter Yes to print the kanban quantity on each kanban card

Print Barcode – Item Number Enter Yes to print an item barcode on each kanban card

ID: Enter Yes to print a kanban ID barcode on each kanban card

User Reference: Optionally, enter an alphanumeric reference to this kanban loop

Order Quantity Multiple: Optionally, enter the number of kanbans that serves as the lowest common denominator for system sizing calculations.

Ship Delivery Pattern Code: Optionally, enter a one or two character code specifying the required routing ship or delivery patterns for this kanban loop.

SDT Code: Optionally, enter a two character shipping delivery time code associated with this kanban loop.

Point of Use Location: Optionally enter a code representing the location where the kanban item supplied by this loop is used.

Delivery Location: Optionally, enter a code representing the location where the kanban item supplied by this loop is used.

Comments: Set to Yes to add additional comments to this kanban loop.

Press enter or click on next to continue

Dispatch List: Indicate whether to allow selection of this kanban when dispatch lists are processed.

Kanban Label: Enter the optional identifier for a kanban label definition associated with this loop.

Repl Time: Enter the time required to replenish the item. This value is used in the calculations performed by the kanban workbenches

FIFO Time: Enter the amount of time required for this item to complete the total number of internal FIFO processes defined for the kanban loop.

Ext: Enter the amount of time required for this item to complete the externally performed FIFO processes defined for the kanban loop

Card Reporting: Specify the method used for kanban card piece reporting.

Fractional Kanban: Specify the fractional kanban % for this loop. It can not be greater than 99%.

Run out Option: Enter Yes if the source that supplies this item runs the quantity needed to use the entire supply of a given material regardless of the kanban quantity.

Accumlator Type: Specify how the system accumulates replenishment cards for this kanban item after you record them using Kanban Consume/Post.

Accumulator Interval: When Accumulator Type is set to Time, specify how often the system can authorize empty kanbans for this item, assuming that the total of empty kanbans has reach the value in Order Quantity.

Next Date and Time: when Accumulator Type is Time or Schedule, the system calculates and displays the next date and time that Accumulator Monitor will check for empty cards for this loop, based on the value of Accumulator Interval or the Work Day and Time settings.

Work Day and Time: When Accumulator Type is Schedule, specify whether the system can authorize empty kanbans for this item on this day of the week, assuming that the total of empty kanbans has reached the value in Order Quantity.

Press enter or click on next to continue

Blanket PO Release: Specify whether dispatch list processing attempts to release a PO from a blank order.

Fax Dispatch List: Indicate whether to allow selection of this kanban when dispatch lists are processed in fax format.

Source Fax: Enter the fax number for the supplying source

Src Fax: Enter the fax number for the supplying source

E-mail Dispatch List: Indicate whether to e-mail dispatch lists for this kanban.

Source E-Mail: Enter the e-mail address for the supplying source

EDI: enter Yes to generate dispatch lists for this loop in EDI format for export to the loop supplier using EDI eCommerce.

Press enter or click on next top continue

Regeneration Enforcement: Specify how cards are managed for this loop when they are recorded in one of the programs on the Kanban Transactions Menu and the system determines that cards should be regenerated.

Kanban Cycle Enforcement: Indicate the level of minimum kanban loop cycle enforcement. Valid values are none, warning and error.

Quantity Violation Enforcement: Use this field in combination with Rounding Threshold to control how the system managed partial kanban quantities for this loop during certain automated processing functions.

Rounding Threshold % Specify the % of kanban size the system uses to round off partial kanban quantities in determining the number of cards to select for automated processing

Minimum Cycle: Enter the minimum kanban loop cycle time.

Maximum Cycle: Enter the maximum kanban loop cycle time

Decrease at Consume: Specify whether you want to have cards that are no longer needed removed from this loop the next time they are consumed, as well as whether the system prompts for confirmation before removing them.

Component/OP Transactions: Indicate whether the system should automatically generate the following types of transactions when this kanban controlled item is received into the supermarket:

  • Backflush components from the BOM
  • Record labour based on routing information
  • For loops that include subcontract operations, create a purchase receipt.

PO Receipt Data Entry: Specify whether the system prompts for purchase order receiving information when a replenishment card from this loop is recorded in Kanban Fill/Receive.

Lot Entry: Specify whether the system prompts for a lot number and reference when a replenishment card from this loop is recorded in Kanban fill/Receive.

Impact Inventory: Indicate whether kanban transactions for this item will impact inventory and reference when the card is recorded.

Use Control Prog Tran Settings: Specify whether sequence enforcement and automatic card print values for this loop are determined by Kanban Control or by Kanban Master Maintenance.

Inventory Location: Enter the code representing the location where inventory is stored for this loop.

Modify Inventory Data: Specify whether users can update default values when recording kanban fill/receive or ship transactions for this loop.

Modify Inv Threshold: Specify the maximum % of the kanban quantity that is considered an acceptable difference between the kanban quantity and the quantity actually recorded in Kanban fill/Receive or Kanban Ship

Receipt Shortfall: Specify the cumulative difference between the expected total receipt quantity and the actual receipts.

(0 vote(s))
Helpful
Not helpful

Comments (0)
Post a new comment
 
 
Full Name:
Email:
Comments:

BSD Support Center
Copyright@ 2009 - 2014 BSD Solutions