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!
Similar Messages
-
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
AnkurHi,
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. -
Dear Guru,
Ist possible to use Quota arrangement in KANBAN external Procurement (Scheduling Agreement)?
If so, please advice me how to do it... i am new to KANBAN.
Regards,
SenthilHi Kumara,
As per my knowledge Quota Arrangement is not possible to use in KANBAN with Schedulling Agreement.
However pls find below the process steps for KANBAN WITH SCHEDULING AGREEMENT:
You can carry out KANBAN with Replenishment Strategy- External Procurement in following two ways :
1. 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).
2. 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).
Hope this helps.
Revert if any doubt and reward points if useful.
Regards,
Tejas -
KANBAN - STO (error : Goods movement not possible with mvmt type 351)
Hi,
I have configured KANBAN STO in the system which is working fine.
I am able to empty the bin and create STO (purchase orders)
But when I select a bin and try to make it full, system gives error message:
"Goods movement not possible with mvmt type 351"
In KANBAN STO replenishment strategy, I have used movement type 101,
I m little confused from where this 351 movement type is coming from.
Please help resolvethis issue.
PavanHi,
Below is the entire message:
Goods movement not possible with mvmt type 351
Message no. M7096
Diagnosis
You have entered a movement type that has not been defined for this transaction/event.
Procedure
Choose another movement type.
You can choose the movement type as follows:
If you know the movement type, enter it directly in the Movement type field.
Choose the movement type via the menu option Movement type.
Choose the required movement type from the possible entries.
If you do not find a suitable movement type, exit this function and choose a different goods movement from the Inventory Management menu.
Pavan -
Kanban with status sequence WAIT EMPTY FULL shows '-' neg. sign after GR
Hi PP
I am using one control cycle in kanban with replenishment strategy
stock transfer where in stock transfer using "stock transfer with
reservation".
I made one bin empty at the demand source using t code PK13N
But when i am doing transfer posting using migo against the
replenishment element created by emptying the kanban , i am getting
messge "NO KANBAN EXIST".
why system is behaving abnormal i mean trnasfer posting not happening.
system is not behaving normal.If i forcibly do the posting ignoring
warining message above mentioned it shows no change in bin status ,
then if i manually change status to green by PK13n it makes it green
but wth negative sign.This behavior is quite abnormal as i have
sufficient stock to get transfered too.
status sequence is with three statuses WAIT EMPTY FULL
Please help in this regard
Even if i use this status sequence for inhouse production also same problem is theirHi,
Check the settings for replenishment strategy u have selected for the material.
OM11 - Production Relenishment strategy
OM12 - Procurement Replenishment strategy
as in ur case u are now procuring that element so, check order type in ur replenishment strategy
Regards
Samunder Singh -
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 ??????
ShankarHi ,
Please confirm if a material document is posted when u did co15 or MIGO ..
regards
Krishna -
PK07 AC: Average consumption per time unit
Dear guru ,
in Kanban Calculation (PK07) with this below formula how the system determine the AC
Average consumption per time unit ?
6.quantity per kanban i*
Quantity per kanban = RT * AC
SF
AK - C
7.
NK: Number of kanbans
CONT: Quantity per kanban
RT: Replenishment lead time per kanban
AC: Average consumption per time unit (from dep.reqmts)
SF: Safety factor (proposed value 1)
C: Constant (proposed value 1)
Thanks.Not answered.
-
Cross docking - planning not possible
I have set the customizing settings (maintain warehouse level settings ; defince cross-docking relevancy for movement type 101 and 350 ; maintain number rangers) for cross docking but I am still not able to link an inbound TR to a outound TR (same quantity / material).
The error messages "No matching inbound documents found" occurs when I try to "Plan the cross-docking".
Scenario
outbound TR for KANBAN WM replenishement (mvt 350)
inbound TR for goods receipt posting (mvt 101)
Thank you in advance!Hello,
Can anyone reply this?
I don´t have a solution yet.
Thanks a lot,
Jesus -
XI and R/3 Installation on One System
Hi,
I am new To XI and I want to install XI and R/3 in My Local System. Can i install both in one system (OS)? If yes, what is the minimum requirement for this?
If any one have did this, please help me.
Thanks,
SridharHi Sridhar,
Download this Doc and Fallow...
http://help.sap.com/bp_scmv150/documentation/SCM50_system_reqs.doc
Fallow the below documentation...
System Requirements for
SAP Best Practices for SCM 5.0 Scenarios
Use
The objective of this document is to help system administrators to prepare an SAP SCM system for the installation of one or more SAP Best Practices scenarios and to ensure the system setup meets the requirements for the installation.
This document does not provide information on how to set up the entire SAP SCM system, itself, but provides you with useful additional information and troubleshooting tips.
System Landscape
To install one or more of the SAP Best Practices for SCM scenarios from this CD, you should refer to the system landscape described below and compare it with your own existing system landscape as an installation prerequisite.
Please note that the support package levels indicate the minimum support package level your system landscape should have. If higher support packages exist, we recommend that you install the highest available support package.
To install and use any SAP Best Practices scenario, you must have installed an SAP R/3 and an SAP SCM system.
SCM 5.0: Complete Version
SAP SCM 5.0 contains the following business application components on one system platform:
SAP APO 5.0
SAP EM 5.0
SAP ICH 5.0
The following table provides an overview of the software component details of the SAP SCM system:
Software Component Release Level Highest Support Package Short description of Software Component
SAP_BASIS 700 0007 SAPKB70007 SAP Basis Component
SAP_ABA 700 0007 SAPKA70007 Cross-Application Component
ST-PI 2005_1_700 0001 SAPKITLQI1 SAP Solution Tools Plug-In
PI_BASIS 2005_1_700 0007 SAPKIPYI77 Basis Plug-In (PI_BASIS) 2005_1_700
SAP_BW 700 0007 SAPKW70007 SAP NetWeaver BI 7.0
SAP_AP 700 0004 SAPKNA7004 SAP Application Platform 7.00
LCAPPS 2005_700 0002 SAPKIBHD02 LCAPPS 2005_700 : Add-On Installation
EA-IPPE 400 0003 SAPKGPID03 SAP iPPE (EA-IPPE) 400
SCM 500 0004 SAPKY50004 Supply Chain Management 5.0
SCM_BASIS 500 0004 SAPK-50004INSCMBASIS SCM Basis 5.0
QIE 200 0004 SAPK-20004INQIE Quality Inspection Engine 2.00
BI_CONT 702 0002 SAPKIBIHP2 Business Intelligence Content
Optimization Server Version:
Identifier Version
CTM01 5.0_REL SP04, 356375
DPS01 5.0_REL SP04, 356375
CS01 5.0_REL SP04, 356375
SEQ01 5.0_REL SP04, 356375
SNP01 5.0_REL SP04, 356375
VSR01 5.0_REL SP04, 356375
Live Cache SP05 (LCA50.05, LC 7.6.00.22)
LiveCache version: KERNEL 7.6.00 Build 022-123-119-055
DBM server version: DBMServer 7.6.00 Build 022-123-119-055
Operating system: SunOS
LCA version: Module 50 Build 05
SAP APO GUI
We recommend that you install the SAP APO specific SAPGUI add-on, which is required for certain business transactions.
SAP ECC System
SAP ECC Enterprise with Extension Set 1 (for the SAP Best Practices scenario Fulfillment Visibility we used an SAP R/3 Enterprise system with Extension Set 2)
Software Component Release Level Highest Support Package Short description of Software Component
SAP_ABA 700 0007 SAPKA70007 Cross-Application Component
SAP_BASIS 700 0007 SAPKB70007 SAP Basis Component
ST-PI 2005_1_700 0001 SAPKITLQI1 SAP Solution Tools Plug-In
PI_BASIS 2005_1_700 0007 SAPKIPYJ77 PI_BASIS 2005_1_700
SAP_AP 700 0004 SAPKNA7004 SAP Application Platform
SAP_APPL 600 0004 SAPKH60004 Logistics and Accounting
EA-IPPE 400 0004 SAPKGPID04 SAP iPPE
EA-APPL 600 0004 SAPKGPAD04 SAP R/3 Enterprise Add-On PLM, SCM, Financials
FINBASIS 600 0004 SAPK-60004INFINBASIS Fin. Basis
BP-ERP05 600V2 0000 SAP Best Practices All-in-One based on ERP 2005 (ECC 600)
SAP XI System
If you want to install the SAP Best Practices scenario Supplier Managed Inventory, Release Processing, Responsive Replenishment, Contract Manufacturing Procurement & Supply Network Inventory, Kanban-based Replenishment, you also need to implement an SAP XI system.
Software Component / PI Content Release Level Highest Support Package Short description of Software Component / PI Content
SAP_BASIS 700 0007 SAPKB70007 SAP Basis Component
Content for SAP BASIS 700 0007 XI content for SAP BASIS 7.0
Content for SCM 500 0004 XI content for SCM 5.0
Content for SCM BASIS 500 0004 XI content for SCM BASIS 5.0
Non-ABAP components, such as the Integration Builder and the Integration Repository, must also be installed and have the respective support package levels.
For uploading the content in the XI System, refer to SAP note 836200.
Checklist after the System Setup
SCM Menu
After you have installed the SCM System, you may have to set up the menu that you want to use.
To do this, access transaction SE38 and run the report /SCMB/SM_VERS.
Choose Full Version and then, choose Execute.
Check Planning Version 000
In your SAP SCM system, use the following path:
SAP Menu  Advanced Planning and Optimization  Master Data  Planning Version Management  Model and Version Management
Make sure that the planning version 000 Active Version is available.
If this planning version is not available, this means that the LiveCache has not been initialized. Proceed with the LiveCache initialization before you start with the installation of any SAP Best Practices scenario.
Check that PSE services have been activated
Use transaction strust in your SCM system. All services should have a green light. If it is red, activate all of them. There is no need to reboot the system afterwards.
OPTIMIZER
1. Checking that the Optimizer has been installed
Transaction SM59  RFC Destination  OPTSERVER_CTM01  Test Connection
If the connection cannot be established, this may be due to the following reasons:
the Optimizer has not been installed
an error occurred during the installation of the Optimizer
2. Checking that the Optimizer SPs have been installed
Open transaction /SAPAPO/OPT09. The Optimizer Support Packages should be identical to the Support Packages of the SCM system.
Ensuring that the APO relevant PI Settings are activated in SAP ECC
You have to make sure that the business transaction events are active in the SAP ECC system. Only if these events are active for the SAP APO integration, will changes to the transaction data be transferred from the SAP ECC system to the SAP APO system. This setting should have already been performed; this is just a reminder in order to avoid possible problems later on. Use the following procedure:
In your SAP ECC system, open the transaction BF11.
Confirm the message The table is cross client.
On the Change View: Application Indicator: Overview screen, check that the applications ND-APO, PI-EM and NDI are active, i.e. selected. If they are inactive, select the check box to activate them.
Choose Save and go back.
Web Communication Layer (WCL)
Ensure that the WCL is installed correctly: Usually the WCL should be connected to the client 001 of the SCM system. Use transaction /saptrx/wcl_search in the SCM system to open the WCL. If a logon pop-up appears, then the WCL is set up correctly. If the message WCL is not installed... appears, the respective set up settings should be checked and corrected, if necessary.
Additional Information
For additional information on issues such as architecture, sizing, platforms, and upgrades, refer to following page on the Service Marketplace:
alias /SCM  SCM Technology
For information on system monitoring, system administration, volume testing etc., check SAP note 572003. You can also refer to the Service Marketplace, using the alias /SCM  SCM Technology  Table of Contents  Solution Management  Best Practices for mySAP SCM Solution Management.
Thanks,
Satya Kumar.. -
Advantages of Implementing Demand Planning in APO
Hi All:
One of our company's business units is exploring the possibility of implementing their Demand Planning in APO. Since their business closely resembles retail, they do not run MRP in ECC to replenish. Instead they do Kanban for replenishment. Hence they do not need Independent requirement in ECC.
The as-is forecast model is a simple spreadsheet that they use that is used for financial forecasting. They have a lots of SKUs and with spreadsheet aggregation and disaggregation is a night mare. Hence they have products sitting in their inventory, worth millions of dollars that has not been sold yet for a year. In essense the top-level forecast data has too many errors. They also use this to forecast how much of components they have to procure. Again, they have millions of dollars work of components sitting in our inventory.
So, they are looking to implement their DP in some other software. Since we have APO, APO could be a choice. But we have to justify the cost involved.
They will not need APO to send back IR back to ECC.
Followiing are the benefits we see:
1. Highly integrated with ECC and hence forecasting will be based on their Sales and invoice history.
2. Since their products are seasonal, APO can offer advanced forecast methods to forecast SKUs as accurately as possible.
3. Ease of use.
4. Right now, the spreadsheet is accessible to one user at a time and been shared thru emails. This will change with APO
5. They could use DP-BOM to forecast component and help reduce components inventory
6. An integrated system that will sent forecast to CO-PA on a monthly basis.
Can you guys help me with anything else that will benefit the business? Any input will be of great benefit.Hi,
before to begin: I don't really understand what you are saying: you say the forecast is not use for planning, however your think it is the cause of overstock... how can that be?
I understand the logic for componenents, but not for finish good here
Anyway, regarding your questions:
Of course DP will help you too, and the benefits you emntioned are good.
However I suggest you to do a bigger analysis of your business needs... it looks ot me that you will need more than DP.
You could use SNP to plan your finish good and components (or use a strategy such as planning at assembly level).
If your biggest challenges in inventory level then SNP is the tool that will give you a better visibility here.
I personnally think that DP BOM should be use only is specific cases. You better have to plan your component in SNP, which will be far more flexible.
In one sentence, I think that if you do decide for a DP implementation now, you biggest benefit should be: later on you will be able to use SNP for planning.
Well that is what I think....
Good luck for your challenges!
Julien -
Gurus
How does PK07 T Code give KANBAN Calculation?? I mean what is the difference between this and what we enter in PK01. In PK01 also we enter number of kanbans & kanban quantity viz manually but how does PK07 give the output?
I am bit confused as on what basis system is generating kanban calculations???
Please give your comment & correct me if i am wrong at any point
RgdsDear Vicky,
The basic difference between PK01 & PK07 is :
PK01 : Tcode used for simply creation of KANBAN Control Cycle which you can say same functionality as in case of PKMC ( Control Cycle Maintanance).The main thing here is you can simply create control cycle with no. of Kanban bin, kanban qty, replenishment strategy. However, you can;t involve MRP & LTP data in case of PK01 or even in PKMC.
PK07: This Tcode is used for creating change control cycles in order to facilitate MRP & LTP data in calculation of control cycles which is not possible in case of PK01/ PKMC.
In short, we can say that PK07 provides more depth / drilldown in control cycle evaluation which is not available with PK01 / PKMC.
Hope this helps clear your doubt.
Regards,
Tejas -
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: 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,
ArturoHello,
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 -
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
jayAlso 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 in Subcontracting
hello friends,
I want to know that whether replenishment is possible in subcontracting,i.e. suppose i want to maintain a stock of 1000 finished components at vendor,whenever he delivers material i will issue him raw material for that much quantity only.the order will be an annual order for the order say 1000000 nos.Hi,
The quantities of the components to be provided to the vendor are entered into the stock of material to be provided to vendor. This stock has the following features:
It is managed as part of your total valuated stock, and is available for MRP.
It is only managed at plant level, since it is not stored at your own company but on the vendor's site.
Two stock types are possible:
unrestricted-use stock
quality inspection stock
Stock can be transferred between the two stock types. Withdrawals can only be posted from unrestricted stock, however.
You can take a physical inventory of the stock of material to be provided to vendor.
<b>It is only managed at plant level</b>
BR
Diwakar
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