KANBAN for automobile

Hi
Can anybody help me with KANBAN cycle
i have tried making it , i have succeeded till ctrl cycle and making bins green on gr internal and external both .
But some other functions like creating proposals and with MRP ....not able to understand
I have to show the full sycle external and internal.
Is anybody having clarity on this , can share with me .
Would be of great help
Thanks
Amit

Hi,
Detailed for each of the above find as below :
KANBAN PROCESSES , PROCEDURES AND PRE-REQUISITES:
1. Stock transfer from Main Stores to Production Line
Basic rules and Prerequisites:
u2022 MRP type must remain as it has been like u201CPDu201D or u201CVBu201D or any active MRP type.
u2022 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).
u2022 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
u2022 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.
u2022 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).
2. External procurement from Vendor to Main Stores
Basic rules and Prerequisites:
u2022 MRP type should be u2018NDu2019 in MRP1 view of material master.
u2022 Availability check should be u201CKPu201D in MRP3 view of material master.
u2022 Material received from vendor is directly posted to unrestricted stock. Inspection at vendors place or vendoru2019s process control to ensure rejection free material. Inspection set up in Material master should be inactive.
u2022 Backflush is not required and Material is issued against a Pick List for Production Order.
Process steps:
1. Create supply area for Main stores. TC: PK05
2. If required, extend the material to main storage location. TC: MMSC
3. Make the necessary changes in the material master as explained above.
4. Create scheduling agreement. Put kanban indicator (X) in the additional data of item.
5. Create Kanban control cycle. TC:PKMC
6. Print the barcode. TC:PK17
7. Set the kanban status to EMPTY by scanning the barcode. TC: PKBC. A Schedule line will be generated for the supply of material to main stores.
8. View the demand source view. TC: PK13n
9. When the material is received at Gate, perform goods receipt into blocked stock (movement type 103). TC: MIGO
10. Once the material reaches Main stores scan the barcode to FULL. TC: PKBC (At the background GR with 105 movement will happen).
3. External procurement from Vendor directly to shop
Basic rules and Prerequisites:
u2022 MRP type should be u2018NDu2019 in MRP1 view of material master.
u2022 Availability check should be u201CKPu201D in MRP3 view of material master.
u2022 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).
u2022 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
u2022 Maintain KN01 storage location in the field - production storage location of MRP2 view in the material master. Back flushing will take place from this location. Field - Storage location for external procurement should be KN01 in the material master.
u2022 Material received from vendor is directly posted to unrestricted stock. Inspection at vendors place or vendoru2019s process control to ensure rejection free material. Inspection set up in Material master should be inactive.
Process steps:
1. Create supply area for kanban stores (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 scheduling agreement. Put kanban indicator (X) in the additional data of item.
5. Create Kanban control cycle. TC:PKMC
6. Print the barcode. TC:PK17
7. Set the kanban status to EMPTY by scanning the barcode. TC: PKBC. A Schedule line will be generated for the supply of material to kanban store.
8. View the demand source view. TC: PK13n
9. When the material is received at Gate, perform goods receipt into blocked stock (movement type 103). TC: MIGO
10. Once the material reaches shop, scan the barcode to FULL. TC: PKBC (At the background GR with 105 movement will happen).
4. In house production (Between one sub-assembly line to Main assembly)
Basic rules and Prerequisites:
u2022 MRP type should be u2018NDu2019 in MRP1 view of material master.
u2022 Availability check should be u201CKPu201D in MRP3 view of material master.
u2022 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).
u2022 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
u2022 Maintain KN01 storage location in the field - production storage location of MRP2 view in the material master.
u2022 Maintain u2018Kanban Production schedule profileu2019 in Work scheduling view of the material master.
u2022 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).
Tcodes used in KANBAN:
Create Supply Area
(Tcode: PK05)
Create Control Cycle
(Tcode: PKMC)
Kanban Transaction through Scanning or
Manual operation.
(Tcode: PKBC)
Event Driven Kanban u2013 Requirement generation.
(Tcode: PK23)
Goods Receipt u2013 India Specific Process
(Tcode: PKBC)
Kanban Board u2013 Demand Source view
(Tcode: PK13N)
Kanban Board u2013 Supply Source view
(Tcode: PK12N)
Kanban Evaluation
(Tcode: PK18)
Kanban Correction
(Tcode: PK50)
Kanban Locking & Deleting
(Tcode: PKMC)
Hope will work for you.
Regards,
R.Brahmankar

Similar Messages

Kanban for SAubcontracting Items

Hi all,
We are using Subcontracting for some of our sub-assemblies,we send the components required for these sub-assemblies to vendor against a PO against the movement 541.and when we receive the sub-assembly from vendor we make GR for sub-assembly(mvmt 101) and components get backflushed from vendor stock(movement 543).Presently all this system is handelled manually.
Now we want to take this process in KANBAN.Can we use Scheduling agreement for subcontracting activity.
Pl. suggest how we can use KANBAN for this activity.
Thanks & Regards
Sandeep

Thanks Tajuddin ,
I have tried creating the scheduling agreement. but the problem with sch. agreement is we can not send the components against it unless we trigger the schedle line(BOM doesn't get exploded when we try to do stock transfer[541 mvmt] w.r.t this sch. agreement)
In our case we are sending the components required for making the subassembly in big lots(e.g. for 15 days requirement) and while getting the subassemlies we want to use SAP KANBAN ,so that schedule lines get triggered whenever we trigger the KANBAN and vendor supplies us the subassemblies as per those sch.lines .
Pl. suggest
regards
Sandeep

Kanban for in house mfg items

We have a BOM with item A as FG, B as SFG & C as raw material.
A & B are produced using Repetitive mfg with REM profile GR/GI together.
B is to be handled using kanban, for which Supply area, Control cycle are created as well as Replenishment strategy & Status sequence is configured.
The requirement is as follows:
(1)On running MRP for item A, system should generated planned orders for item A & PRs/schedule lines for item C.
(2)On production confirmation of item B using transaction code:MFBF, the bin status should automatically become FULL from its initial status EMPTY.
(3)On production confirmation of item A using transaction code:MFBF, the bin status for its component Bshould automatically become EMPTY from its status FULL.
Similarly, the movement bin status for item B automatically becomes EMPTY, it should trigger a Planned order generation in MD04 list for item B.
Regards,
Ranjeet

Hi,
If u want to handle B(HALB) with kanban system then
1) Create supply area in the mfg storage location
2) Create control cycle with replenishment strategy"In house Mfg" strategy type "Planned order with MRP".
So once u run the MRP for material A(FERT) then planned gets generated against A and B also.
Once u trigger the kanban card for material B then one planned order gets generated and MRP generated planned qty gets reduced.
EG:
MRP triggered planned order qty is 100.00Qty
If ur bin qty is like 20.00qty
Once u trigger the kanban card then
20.00qty planned order gets generated (KANBAN planned order)
Then MRP triggered planned order reduced to 80.00qty.
Once u trigger the kanban card bin becomes "Empty".
After Mfg execution production confirmation done thr' T CODE PK41 not thr' MFBF.
Once u execute PK41 transaction bin status changes to full automatically.
Regards
Vijay

KANBAN for external Procurement and Purchase order

Good morning
I am working with kanban for external procurement
Through PKBC-transaction I set "empty status" and SAP creates the purchase order
is it possible to create 1 purchase order about 2 or more item?
in which way?
thanks

Hi,
Thanks for reply... Can you breif me the procedure to achieve it..In material master, where i need to mention it....
Regards,
Subhash

Kanban for eWM materials

Greeting,
We are trying to enable Kanban for a location that is managed by eWM system. our production system is 4.7 R/3 while our eWM platform is SCM 7.1. So when we try to use the standard kanban transaction to create control cycle we received the message <Kanban replenishment for wm storage location is not possible>. So since we don't interface our production system with eWM and the only thing that we need to do in eWM system is to PGI a material we are thinking to do core mode change.
More explannation: since the only check in PK01,PK02, PK03 is only one set of code where it check if the location is exist in T320 table then we are thinking to comment this part of the code and then we will able to proceed with creating CC for warehouse managed materials without any other issue.
So the question, did anybody has same issue, or tried to do same solution that I suggested here?
if yes, what was the impact of this on the system.. any thing that we should concern about and test it after we apply this change?
if no body used this solution, can you think of any risk we might encounter because of this change?
Thanks

Hi,
Thanks for reply... Can you breif me the procedure to achieve it..In material master, where i need to mention it....
Regards,
Subhash

Kanban for finished goods (discrete manufacturing)

Hi gurus,
I am using kanban for finished goods(with MRP) to triggers production order(discrete manufacturing). If i set the status "empty" system is creating a planned order directly. It is not coming for MRP run. I suppose, that planned order should be created through MRP run(since i am using kanban with MRP). Can you please tell what settings i need to be checked?
Regards
Rajib Pathak

Hi,
Pls. find details about settings for KANBAN With MRP:
KANBAN With MRP
Prerequisites
In this process, the storage location assigned to the supply area is not excluded from MRP.
If a material is planned and procured with MRP, you must make the following settings:
You must maintain a valid MRP type for the material. This means, the setting "ND" (No planning) is not allowed.
You must maintain all other control parameters required for MRP for the material.
You must maintain a repetitive manufacturing profile (in the MRP data screen) for replenishment strategies with a cost collector (in-house production with run schedule quantities, manual KANBAN). In the SAP standard system, a profile is available that is specially intended for KANBAN, that is, using this profile, the system creates a cost collector without a run schedule header.
Features
Here, the total production quantity or the procurement quantities of a certain period are planned in the planning run and the replenishment elements are also created in the planning run. For in-house production, you can use either Repetitive Manufacturing or production orders to plan the production quantities per period. For external procurement, all the standard replenishment elements are available. The replenishment elements created in the planning run, however, are not intended to trigger production or replenishment directly. Instead, they exist to provide the supply source with a preview. Actual production and material flow are controlled and triggered by setting the kanban to FULL and EMPTY. Backflushes and goods receipts are posted with no reference to the kanban. This means that you can backflush daily quantities, for example.
In this procedure, the following is valid for materials with BOMs:
Components that are used in KANBAN materials can be planned using any one of the MRP procedures. However, the system has to be organized so that the supply source does not produce the material for the replenishment element created in MRP immediately but awaits the kanban request.
As the system creates preview data in the procedure with MRP, it is particularly useful for replenishment with run schedule quantities (Repetitive Manufacturing) and scheduling agreement releases.
HOpe this helps.
Regards,
Tejas

Which macbook is best for automobile student?

I am taking automobile engineering course & I need a laptop.. Please give me a right suggestion!
Which macbook is best for automobile student?

Any of the new MacBook Air or MacBook Pro models will do. Check their features at Apple.com > Mac. The Air and Pro models are now very close to each other with the Air a little less expensive and a little lighter (3 vs. 3.5 lbs.). I would purchase 8 GB of RAM no matter which machine you buy.
The question is how much permanent (SSD) storage do you need? 128 GB, 256 GB, more? You need to decide this up front and you cannot increase it once it is delivered so choose carefully. How much storage do you use on a current Mac or PC? How much additional storage do you plan to use?
If you undersize the SSD storage all is not lost. You can offload seldom-used data onto an external hard drive. However it is easier to manage the storage if it all fits on your system drive.
Also check out refurbished Macs at http://store.apple.com/us/browse/home/specialdeals. These come with the standard Apple one year warranty.

Tax Structure in US for Automobile industry

Hi All,
In India, CIN will be used to maintain Sales tax, local and central tax for automotive Industry like for Maruti or Tata Motors for vehicle sales.
Similarly what tax structure is used in USA for automobile Industry.
Regards
Nidhi

Check this thread
[Re: Tax pricing procedure for USA / Canada|Tax pricing procedure for USA / Canada;
thanks
G. Lakshmipathi

Can we apply labview for automobile applications?

hi,
can we use the labview for automobile simulation like simuation of battery, motor etc..

chandhu wrote:
can we use the labview for automobile simulation like simuation of battery, motor etc..
Yes! See the following link...
http://www.ni.com/automotive/
LabVIEW Champion . Do more with less code and in less time .

KANBAN for 311 MT with WM Active

Hi Experts,
In one of my requirement, we want to move the stock from yard location to production location using KANBAN board.
This will be a simple 311 movement from inventory management point of view. We have Warehouse Managed storage locations already. While setting up the replenishment strategy for KANBAN using CLASSIC Control Cycle what steps we have to map in the system?
Regards,
Shailendra

Hi,
Please refer below link for your query. Thanking you.
http://help.sap.com/saphelp_40b/helpdata/en/cb/7f8bc443b711d189410000e829fbbd/content.htm

Kanban for finished goods

Hi Gurus,
In my current project our client using kanban in the following way........they are doing SOP for FG to get the raw procurement plan and using Kanban to triggres production of FG.......they have three stock level for FG with a max. limit.......when stock falls below any level it triggers production....and if it falls the minimum level it triggers production with a warning.....................Can you please help me how that can be mapped with SAP
With
Thanks
Rajib Pathak
Mombasa
Kenya

ooook

KANBAN For FG

Hi Gurus,
In my current project my client is using kanban in the following way........they are Using SOP only to do the raw material procurement planning and using KANBAN to triggres production of FG where they have three stock level for FG with a max. limit.......when stock falls below any level it triggers production of FG....and if it falls below the minimum level it triggers production with a warning.....................Can any body please help me how it can be mapped with SAP.
With
Thanks
Rajib Pathak

1. First think i like to put a question is on the Manufacturing principle that is used here..if you tell they use kanban..then they can only manage with the status..
2. The status can be like full ,empty,inproces,wait etc..
3. In case if they are managing the production through manual control process like min,max stock level then the same cannot be replicated in the SAP.
4. BUT sap will give them a good functionality in the Kanban process level..but again the question comes since this is for the FG whether they want to wok with mrp or without MRP has to be validated...
surely you can demo them the standard kanban functionality with simple technique which can give them a fair idea of what to decide
reg
Dsk

A trigger blocking function for control cycle in Kanban

Hi,
I wantet to change the status in Kanban. I get this error u201CA trigger blocking function was defined for the control cycle in the replenishment strategyu201D. I don't want to set a period of blocking function. how can I deactivate it.
Thanks

Hi,
Pls. check the following setting :
First in PK13n ( KANBAN Board) check whether X is marked with KANBAN Number e.g. 1X.
If so then replenishment will not be triggered because KANBAN is locked.
To unlock the KANBAN pls do the following :
Go to -
> PKMC ( Control Cycle Maintanance) in Change Mode----> Select Control Cycle -> Go to Display Control Cycle ( Glass Icon)--> on top of details of kanban cycle choose option ---> Display Kanbans ( Spectacle Icon )
Select it and go inside : Inside pop up appearing check first Column : Lkln ( Lock Indicator).
Remove the tick in check box of lock indicator for respective KANBAN for which you want to trigger replenishment.
Pls. try above settings and revert back if still problem persists.
Reward if problem solved.
Regards,
Tejas
Edited by: Tejas Pujara on Aug 1, 2008 12:25 PM

Issue in Goods Receipt for Kanban '

Hello
I have two Kanbans for Qty 10 EA
I receive the goods in two steps:
1. GR MVT 103
2. GR MVT 105
When 103 doc is posted for 10 Pcs one Kanban turns to Green for 10 Pc.
When I release the blocked stock again the other Kanban also turns Green though I have received 10 Pcs only
Is there any configuration settings to control this as this happens in Standard Trans MIGO
<< Priority normalized >>
Regards
Avinash
Edited by: Rob Burbank on Feb 28, 2012 1:54 PM

Hi Avinash
The system cannot fulfill your requirements fully, reason being:
- in case of external procurement strategy 0009 the kanban is not linked to the schedule line but the schedule item only. So we have no unique link between the schedule line and kanban.
- the kanban module is called during the process of the GR-posting. Currently the Kanban module does not interpret the movement type. Thus we asssume that the GR is posted into unrestricted stock and the Kanban is set to full. Interpreting the movement type would probably mean a special status which is set when the material is posted into unresticted stock. This is currently not supported.
WORK AROUND 1:
A suggestion would be to set the separate goods receipt flag in the
control cycle.
Your process would work as follows:
1.After the movement with 103 the kanban remains empty with a + sign.
2.After the movement with 105 the kanban remains empty with a + sign
3.You you have to set the kanban to full manually in the kanban board.
In case the manual changing of the bin status is not an option:
WORK AROUND 2:
Please follow the suggestion described in the workaround 1. Then the missing part of the process is to set the kanban to full.
The workaround would be that you should use the user-exit EXIT_SAPLMPKB_001. In the user-exit you should store the kanban id (I_PKPS-PKKEY) in your own table while posting with movement type 105.
Since Kanban does not deal with movement types you should EXPORT the movemnt type into the abap memory from an user exit from the IM. -> In the kanban user exit you have to import it from the abap memory.
For using the kanban USER-EXIT you have to define a status sequence in the kanban customizing with activity UE for the status change from 2 to 5 and assign it to the control cycle.
After that you need an own report which would call the BAPI BAPI_KANBAN_CHANGESTATUS1 with the kanban id from your own table. After setting the kanban to full the report should delete the entry from your table.
The report could be started in a job in a period what you want.
I hope this can help.

External kanban- JIT Idoc set to vendor.

Hello
I am setting the partner profile for the JIT Call in KANBAN for External Procurement.
I have defined as follow:
Partner number 6722334
Partner type: LI
Partner function: OA
Message type: PAB_ORDERS (Quantity release from KANBAN)
Outbound option tab:
Receiver port: SAPDEV
Transfer IDOC immed:
Output mode: 2
Basic type: SEQJIT01 (JIT: IDoc for sequenced/summarized JIT calls)
Message Control Tab:
Application PA :JIT call
Message type: ZDKA-JIT Call EDI
Process code: PJN0 (Generation/export of IDOC orders03 for JIT call)
When I am checking Idoc in ME38 under messages it is showing red
the status process is in error, and the error is below:
No corresponding entry in table JITOIT Message no. JIT00017
I check the table JITOIT and it is empty.
Did I miss some in configuration? Or how that table is to be filled?
Rgs
Edited by: sudhir.R.T T on Nov 25, 2011 12:53 PM

Hi Sagar
For the Confirmation you need to do the customizing for confirmation control, like what would you like to do after the confirmation. Confirmation is an inbound process.
For Invoice you need to complete the customizing under LIV in SPRO- for Invoices received via EDI.
Please go throught the help link for further details.
http://help.sap.com/saphelp_47x200/helpdata/en/a8/b99f58452b11d189430000e829fbbd/frameset.htm
Reward points if useful
Thanks & regards
Kishore

KANBAN for automobile

Similar Messages

Maybe you are looking for