KANBAN in house replenishment

Hi, I got some tricky requirement from my client, could you guys help me with this.
i two work centers namely W1, W2 with storage locations s1, s2 respectively. normally i do stock transfer to W1 kanban supply area K1 from main warehouse W. component C1 needed to make a finished material in W1 will be manufactured in W2 with name C2 which has components D1 and D2 with stock in S2. requirement is they just want to backflush d1 and d2 from s2 whenever kanban bin (for C1) in K1 is empty because they does not care any mfg process of C2 and consider only stocks of D1 and d2 for inventory purpose. iam thinking of creating production order whenever bin is empty and performing confirmation without printing any shopfloor papers so that i can backflush d1 and d2 and can do auto G/R of C2 to s1.
is there any other way to do this scenario without kanban because main purpose is to back flush components from s2.
thanks in advance.

Hello,
Your question is not clear to give correct feedback. Do you want to wprk with multiple KANBANS with production orders?
I am not understanding about the sentence "reduce the amount of production orders"
If you want to work work minimum production orders then you can automate the KANBAN replinishment through MRP.
Raegards
TAJUDDIN

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Kanban: in-house production. relation kanban - replenishment order

Dear Experts,
We are investigating the posibilities of using kanban for in-house production. We work with production orders. I have set the test system so it works with classic Kanban and a replenishment strategy that will create PP production ordres.
The system works OK. When the KANBAn is set to EMPTY (in the kanban board for instance) , a replenishment element is generated. The relation is 1 KANBAN - 1 Production order.
Is it possible to "assign" two KANBANS to a single replenishment element (productio order in my case)? In some cases two or more kanbans will be emptied at the same time (in the KANBAN board for instance), and this would reduce the "noise" in the system.
Somehow in the documentation "PP-KANBAN" manual, inside "KANBAN control. in-house production" some other option to reduce the amount of production orders is mentioned, but not very clearly explained how to do this.
Thanks for your answers,
Arturo

Hello,
Your question is not clear to give correct feedback. Do you want to wprk with multiple KANBANS with production orders?
I am not understanding about the sentence "reduce the amount of production orders"
If you want to work work minimum production orders then you can automate the KANBAN replinishment through MRP.
Raegards
TAJUDDIN

KANBAN ; In-house : working with plnd ord/mrp - 0005

Hi
Iam working on kanban in house production as the replensihment stratergy, i chose option 0005 (woring with planned orders/mrp). I had created the kanbans, triggered replenishment for a kanban, converted the planned order to prod ord, released it, carried out goods movement. Then i change the status of kanban to full( there is a minus sign on kanban saying that seperate GR not carried out,in control cycle i chose sep GR) When i try to withdraw quantity from kanban it says actual qty does not exist in kanban ( i still have the minus sign on kanban saying that sep GR is not posted - i did GR posting once by co15 and the other time thru MIGO), so NOW i changed the kanban status to empty and reversed the empty status to full by using pk31, the reversed kanban bin which is now to status full does not have the minus sign and it says that there is an actual qty of X, NOW i can use pk31 to withdraw qty from kanban...... .....
iam not sure why this occurs or am i missing some information. ...any suggestions why this is happeningh.. ......... .is working with planned orders only for rep mfg or its also for discrete mfg ??????
Shankar

Hi ,
Please confirm if a material document is posted when u did co15 or MIGO ..
regards
Krishna

KANBAN-Inbound deliveries

Hello,
Could you please help me?
We are using the KANBAN functionality for replenishment of raw
materials from our suppliers.
We are using Summarized JIT calls.
Our scheduling agreement type is LP.
We are looking at the possibility of implementing the "Inbound delivery" functionality... basically, we would like to create inbound shipments for raw materials coming in on JIT CALLS.
Is this possible?
Do we need to use agreement type LPA insrtead of LP?
All details you may have would be appreciated.
My email address is [email protected]
thanks a lot.
Frederick

Hi
Use the T.code VL06I - To monitor the Inbound delivery.
Rewards if it helps.
Regards
Prasanna R

Kanban

Hello
I am working on KANBAN process and replenishment strategy as Planned order with MRP.
When i trigger the KANBAN card planned order is created.That will be viewed in the MD04
So my problem is i am not able diff between MRP run planned order and KANBAN triggered planned order.
EG: MRP triggered planned order as 1000000/Stck
KANBAN triggered planned order as 500000/Stck.
So is their any to change the suffixes of planned order number(Stck)

Hi
Check in the planned order, there would be a kanban indicator which would be automatically ticked for kanban generated planned order, the same applies for purch req, po ord etc. Reward points if useful

MRP Strategies that work well with schedule agreements

Hello Experts, We are having a disucsion on using schedule agreements with our consignment process. What MRP Types and lot size keys work with scheduling agreements? One of our managers insists on using reorder point, and everything I have read seems to lead towards deterministic prodeure PD, and an exact lot size. I was hoping you could provide a proven strategy or tips.
Thank you in advance,
Brian

Hello, Thank you both for your quick replies. Our company strategy is a reorder point strategy, that we force our vendors to read off of a web page, but the settings in the system are PD, and usually a 4 week lot size. The MRP data is dumped to the same web page as the reorder point information. It is expected that our vendor is managing the inventory. We also use a PO for the year parked at the end of the year for the entire supply. This method does not allows us to measure the vendor performance.
We are currently have new proposal to use contracts and Kanbans with MRP. Where MRP is used for forecast information and Kanban controls the replenishment by sending a replenishment order to the vendor. This will give us a consumption based process, that can be measured.
The other proposal is to use a schedule agreement with the same reorder point strategy. This is why I asked my question. I don't think that the reorder point strategy works with this type of order. From my understanding the scheduling agreement controls the delivery of the incoming material based on forecast and real demand. Is my understanding correct?
The ulitimate goal is to have a system that provides our material on-time when it is needed. Easy for our vendors, and so we can measure the vendor against. On time delivey and stock outs.

Routing and Control Cycle

hi........
Is there any link or connection between Routing and Control Cycle?...........if there is connection then what are the parameter that are interlinked?.......
thanks in advance
regards
Nilesh

It is correct that there are 2 ways of creating control cycles for materials.
One is thru Kanban way and the other is regular WM way of control cycles.Here for WM control cycles again, it is just the way of driving materials to particular supply area while in kanban, the control cycle is driven with kanban signals.
If you want to define Kanban, you need to identify first what way you would want the replenishment to occur.
There are two options, classic and even driven Kanban replenishment. In the former one, the replenishment is triggered thru kanban signal in kanban board and replenishment quantity is equal to what is mentioned in control cycle.
In a event driven kanban, replenishment is triggered the same way but the quanity of replenishment can differ.
Classic KANBAN:
Quantity of material (target quantity) that is specified for a kanban.
Event-driven KANBAN:
Proposed value for the quantity of material in a kanban that is used by the system when no order quantity is entered at a kanban signal.
AH

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 Replenishment Strategy with Reporting Points

I am trying to implement a SAP kanban system with repetitive manufacturing using reporting points. My problem is that when I change the status from empty to full I get error RM086 - GR with backflush not for reporting point logic with automatic GR option. I get this error regardless of control key (auto GR or not auto GR) setting on the routing. I reading SAP help on the subject; I see there is a page discussing replenishment strategy with reporting points which would infer that there should be a strategy with a similar name in configuration for replinishment strategies for in-house prodution. We are on ECC 6.0 and this option is not available in our system. What am I missing???

Hi,
As you are using In House production Replenishment Strategy , You must define Replenishment strategy for reporting points in Configuration as below:
SPRO->Production>KANBAN>Replenishment Strategies>Define In-house Production Strategies>Working With Reporting Points Replenishment strategy you need to define.
Then assigned this defined strategy in KANBAN Control Cycle in PKMC-->Replenishment Strategy->
Choose In-house Production Radio Button and in front of that select the above defined replenishment strategy to work with reporting points.
Hope this helps.
Regards,
Tejas

Kanban replenishment with WM

I am using Kanban replenishment with strategy stock transfer from a WM managed storage location(strategy 0006).If I put the Kanban status to empty,I am able to generate Transfer requirement.I converted the TR to TO and confirmed the TO.I am able to move the stock from say storage type R01 to 150, but the stock transfer was not happening from the WM storage location to Kanban storage location.I had maintained supply area and control cycle.Also in WM -PP interface ,for Kanban WM movement type 350 was assigned to ware house and storage type.Also maintained storage location control in WM ,for the ware house and storage type(150) and kanban storage location IM movement type 311 is assigned.Combine post.changes is unchecked.What are the other settings to be made to have automatic transfer with mvt type 311 as soon as TO is confirmed?
Thanks
jay

Also you can try the following
1>Within this customizing, there is the option to notify an user id that the goods movement has failed. If you have set up the mail control then you can check at the mailbox if there is any mail explaining why the goods movement has failed
2>check transaction SMQ1 under queue name WMIM* to see if there are any blocked queues. If there are any failed processes, these can be cleared from the blocked queue in transaction SMQ1. (this is because many subsequent processes in WM like auto TO creation is controlled by qrfc and if the rfc queue is blocked the subsequent process will not occur)

Replenishment strategy in kanban

Hi,
I have created replenishment strategy for maintaining in control cycle of kanban.
1) In house production strategy
2) external procurement strategy
3) stock transfer strategy.
But while creating control cycle I couldnot view the strategy 1) and 2).
I could see only 3rd stratgy.
Pl. tell me what could be the reason.

Hi
The Problem is that the Strategy created is not allowed for storage location that is included in planning.
Error msg no PK192
Solution
Change the MRP indicator for the storage location in the material master record.
In MM02 for the material , Plant and Storage location combination select the ind 1 for SLoc MRP indicator in MRP-4 view and chk whether the newly created Strategies are appearing in PK01 or not.
Regards
Brahmaji

Kanban Replenishment

Hi
I am creating the control cycle( Classic KANBAN ) with replenishment strategy External Source , I am not allowed to do.
I am checking the drop menu and error message is coming no suitable replenishment strategy found.
Please maintain the replenishment strategies in Customizing for Kanban
It is surprising because Replenishment stratigies are maintained for the plant when I check the Customizing.
Any help is appreciated.
Regards
Ankur

Hi,
It may be very very late to answer you, but it may be useful to other users.
If you selected the external source strategy in the control cycle, you need to inform in the material master, in the screen MRP 4, in the field 'SLoc MRP indicator' the value '1 - Storage location stock excluded from MRP'. Make sure to access the material informing the center and Storage location, otherwise this field will not be visible.
You do this because the kanban will act as the 'new' MRP for this material.
Regards,
Alejandra.

Kanban replenishment WM to IM

Hi all,
I am working on the scenario to replenish the production floor (IM location) when the inventory goes below certain level.I have configured the kanban stock transfer option 0006, Created a control cycle with 2 containers. I tried to use the trigger quantity in the control cycle but it didnt work. So i used PK13n to manually set the empty indicator. This triggered the replenishment from WM to IM. But I want to automate this by using the trigger quantity. Can some one please provide some insight on how the trigger quantity should be used in this situation.
Also I tried to consume the inventory from the production floor location by charging it to a cost center. But the Kanban container status is still set to FULL status even with no inventory in the location. When does the quantity in the kanban container change?
Appreciate any suggestions.
Thanks

Hi
It is impossible to consider all of the stock (e.g. the sum of quantities for several kanbans in stock.). The triggering quantity is for the quantity of a kanban. e.g. there are 2 kanbans A and B in a control cycle. The trigger quantity 2 and value 3 is maintained for th field 'Trigger replen.' in the control cyle. Then if the kanban quantity of kanban A is resuded to 2 or smaller than 2 the kanban A is triggered the replenishment. Thi is the logic how the trigger quantity works.
Regards.
Leon.

Deactivation of change replenishment in control cycle -KANBAN -reg

Hi,
Our requirement is typical
we give JIT call triggers through PK13N
Based on KANBAN qty , JIT call is triggered
we dont want the user to change the required qty in the JIt call through PJ02
though we have taken out the authorization for PJ02 , its possible to go to PK13N ....select the KANBAN card ---right click -KANBAN information-click on change replenishment ..its again taking to PJ02 screen though we have removed PJ02 authorization
here user is able to change the qty
how to arrest this ?
is it can be made grey (deactive ) through authorization ? which object and field are to be controlled ?
regards,
Madhu Kiran

a

KANBAN Subcontract Replenishment

We have a scenario where we are using KANBAN to manage a subcontract item. We know that subcontract scheduling agreements will not properly deduct the component inventory from the supplier's inventory (543 movement type) and that SAP admits that scheduling agreements cannot be used for this replenishment.
We would rather avoid using purchase orders for the replenishment, as the number of created purchase orders would overwhelm the accounts payable folks.
What other solutions would be available to us to manage subcontract through KANBAN?

It's been explained in the OSS Message 0020079747 0000841607 2009
that
"In Customizing under Logistics Execution ->Warehouse Management ->
Interfaces -> Stock Transfer for Kanban, you assign the WM storage type
(interface) to the KANBAN (demand) storage location and also define the
movement type for the transfer posting from the WM storage location to
the KANBAN storage location (standard 311)."
If you are doing stock transfer with Kanban, the material will be
transferred from the WM storage location via the Kanban interface to the
supply area, which is set in the control cycle. Therefore, the Kanban
interface must be maintained in the customizing specific to each of the
receiving(supply area) storage locations. It is imperative that we have
different interface storage types for each of the receiving Kanban
storage locations.
It is not the question of permitting multiple supply areas rather is the
restriction of using same interface storage type for many supply areas
(belonging to different storage locations). Please check if the Kanban
interface storage type assigned in control cycle under question is
already been defined as the interface for some other Storage location in
which case you may have to define new storage type for each of the
Supply area storage locations!

KANBAN in house replenishment

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