EKANBAN
General
• NORDYNE will be using Classic Kanban Process
• In the classic KANBAN production control method, the demand
source, the supply source and the procedure to be used to
replenish the material are defined in the control cycle as well as the
number of kanbans that circulate between the supply source and
the demand source and the quantity per kanban.
• In this classic KANBAN procedure, the kanban signal always only
triggers replenishment for the kanban quantity defined in the
control cycle. Moreover, you cannot circulate more kanbans than
are defined in the control cycle without changing the control cycle
first.
• Kanban material can be planned with or without MRP
• Kanban process can be used for In-house produced materials and
externally procured materials (Purchased from external vendor)
Process
• Create the Control Cycle in which the information such as No of Kanbans,
qty/kanban, Replenishment strategy, etc can be maintained.
• Create the Supply area in which the information such as Plant, Storage
Location, Person responsible etc will be maintained.
• All these supply area information will be assigned to the Material master.
• Once the Kanban container is empty, the Full container will be converted
to “EMPTY” or the status can be set to “WAIT” system will trigger the
Kanban requirements.
• These requirements can be Containers, Planned orders or Production
orders.
• The requirement strategy can be maintained in the Control cycle.
• Based on the Requirements generated, upon the goods produced or
procured from the external vendor, the Kanban container can be
converted from Empty to Full, automatically and corresponding
transactions like Goods issue or Goods receipt will happen automatically.
• The status sequence of the Kanban can be controlled via the Control cycle.
Expected Improvements
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Closer to Real Time Procurement signals
KANBAN board will improve visibility
No longer required to maintain cards
Containers can be used more effectively
Known Issues
• How to prepare for demand spikes
• Waiting to order multiple containers in one
order with one PO line (very importatant to
business)
• Keeping transaction from eliminating the
gained efficiency.
• Organizational operational change from visual
to electronic (this is a major change in the way
business is done)
KANBAN Control Cycle
KANBAN Master Data
• Unless manufactured in the plant – KANBAN
can not be MRP relevant.
• Assign Container Types to Material Master
• Define Production Supply Areas (PSA)
• KANBAN control cycle per PSA