View
126
Download
3
Category
Tags:
Preview:
DESCRIPTION
Citation preview
New Awesome Lean
Alex AnikiievTechnical Architect
AgendaThe basics of lean in AXConcepts and definitions Architecture
Setting up and generating kanbans Activities on kanban ruleReplenishment strategies
Planning and processing kanbansScheduling boardProcess boardTransfer board
Lean primerOld leanNew lean
The basics of lean in AX
Industry Summit
Concepts and definitionsActivity A single operation or a group of operations needed to provide a product or a service
Production flowA plan modeling a flow of activities needed to provide a product, service or good, from raw material to a customer
KanbanA pull signal to trigger supply for a specific demand/replenishment. Often a physical card or an electronic signal
JobA single occurrence of an activity for a specific signal (kanban)
Architecture (1 of 9)Kanban rule – A material supply policy for Lean Manufacturing
Architecture (2 of 9)Kanban rule – A material supply policy for Lean Manufacturing
Architecture (3 of 9)Kanban rule – A material supply policy for Lean ManufacturingKanban flow – One or more activities included in a kanbanActivityProduction flow
Architecture (4 of 9)Kanban rule – A material supply policy for Lean ManufacturingKanban flow – One or more activities included in a kanbanActivityProduction flowProcess Work cell – A resource group dedicated to Lean Manufacturing
Architecture (5 of 9)Kanban rule – A material supply policy for Lean ManufacturingKanban flow – One or more activities included in a kanbanActivityProduction flowProcess Work cell – A resource group dedicated to Lean ManufacturingTransfer
Architecture (6 of 9)Kanban rule – A material supply policy for Lean ManufacturingKanban flow – One or more activities included in a kanbanActivityProduction flowProcess Work cell – A resource group dedicated to Lean ManufacturingTransferKanban card – Kanban information placeholder
Architecture (7 of 9)Kanban rule – A material supply policy for Lean ManufacturingKanban flow – One or more activities included in a kanbanActivityProduction flowProcess Work cell – A resource group dedicated to Lean ManufacturingTransferKanban card – Kanban information placeholderKanban – A signal for replenishmentJob – Single occurrence of an activity for a specific signal (kanban)
Architecture (8 of 9)Kanban rule – A material supply policy for Lean ManufacturingKanban flow – One or more activities included in a kanbanActivityProduction flowProcess Work cell – A resource group dedicated to Lean ManufacturingTransferKanban card – Kanban information placeholderKanban – A signal for replenishmentJob – Single occurrence of an activity for a specific signal (kanban)
Architecture (9 of 9)Kanban rule – A material supply policy for Lean ManufacturingKanban flow – One or more activities included in a kanbanActivityProduction flowProcess Work cell – A resource group dedicated to Lean ManufacturingTransferKanban card – Kanban information placeholderKanban – A signal for replenishmentJob – Single occurrence of an activity for a specific signal (kanban)
Setting up and generating kanbans
Industry Summit
Kanban rules (1 of 4)Kanban rule A material supply policy for Lean Manufacturing
Kanban rules (2 of 4)ProcessManufacturing
Transfer Withdrawal
Kanban rules (3 of 4)Kanban flowOne or more activities included in a kanban
Production flowDescription
Activity 1
Activity 2
Activity 1
Activity 2
Activity 3
Activity 4
Activity 1
Activity 2
Kanban rules (4 of 4)FixedReplenish a box when emptyApplied to areas where demand is stable over a period of time
ScheduledMRP or planner creates kanbans based on demand or minimum stockMinimum stock event (batch job independent of MRP)Using CTP on a sales orderApplied to areas where demand is fluctuatingFor example, seasonal demand
EventProduce to order or Configure to orderTriggered by an event, for example, creation of a sales order lineApplied to areas where each kanban should cover a specific demand
Mixing replenishment strategies
Fixed kanban (1 of 5)
• Pre-created according to the needed kanban quantity
• The initial number of kanbans is defined manually or it is calculated based on the kanban quantity calculation
• When kanban is empty, a new instance of the kanban is created to replenish the consumed item
• Fixed kanbans cannot be manually firmed. As they only are re-created based on consumption
Kanban for 5 pcs
Activity (Idle)
Kanban for 5 pcs
Kanban for 5 pcs
15 pcs
Fixed kanban (2 of 5)
• Pre-created according to the needed kanban quantity
• The initial number of kanbans is defined manually or it is calculated based on the kanban quantity calculation
• When kanban is empty, a new instance of the kanban is created to replenish the consumed item
• Fixed kanbans cannot be manually firmed. As they only are re-created based on consumption
Kanban for 5 pcs
Activity (Idle)
Kanban for 5 pcs
Customer8
7 pcs
Kanban for 5 pcs
Empty
Fixed kanban (3 of 5)
• Pre-created according to the needed kanban quantity
• The initial number of kanbans is defined manually or it is calculated based on the kanban quantity calculation
• When kanban is empty, a new instance of the kanban is created to replenish the consumed item
• Fixed kanbans cannot be manually firmed. As they only are re-created based on consumption
Kanban for 5 pcs
Kanban for 5 pcs
Activity (Active)
Kanban for 5 pcs
8
Fixed kanban (4 of 5)
• Pre-created according to the needed kanban quantity
• The initial number of kanbans is defined manually or it is calculated based on the kanban quantity calculation
• When kanban is empty, a new instance of the kanban is created to replenish the consumed item
• Fixed kanbans cannot be manually firmed. As they only are re-created based on consumption
Kanban for 5 pcs
Kanban for 5 pcs
Activity (Active)
Kanban for 5 pcs
8
Kanban for 5 pcs
Fixed kanban (5 of 5)
• Pre-created according to the needed kanban quantity
• The initial number of kanbans is defined manually or it is calculated based on the kanban quantity calculation
• When kanban is empty, a new instance of the kanban is created to replenish the consumed item
• Fixed kanbans cannot be manually firmed. As they only are re-created based on consumption
Activity (Idle)
8
Kanban for 5 pcs
Kanban for 5 pcs
Kanban for 5 pcs
Event kanban (1 of 3)• One event triggers one or multiple event kanban rules
• Changes can either modify an existing event kanban (if not started), create a new event kanban or delete event kanbans
• An event kanban is always pegged to one source of demand (sales line, production BOM line, kanban line)
Event kanban (2 of 3)Manual Create an exceptional event kanban
Batch Reccuring batch job in short cycles (every 15 minutes, every hour, etc)
Automatic Event kanbans are created, updated or deleted immediatly with the event
Event kanban (3 of 3)
Manual Batch Automatic
Sales event Allowed Allowed Allowed
BOM line event Not applicable Not applicable Allowed
Kanban line event Allowed Allowed Allowed
Stock replenishment
eventNot applicable Allowed Not applicable
Scheduled kanbanAutomated creation Master planning creates scheduled kanbans for planned kanban orders in the firming fenceCTP calculation creates scheduled kanban for relevant items
Manual creationSupply schedule formManual firming of planned kanbans in the planned order formManual creation from the kanban rule
Planning and processing kanbans
Industry Summit
Kanban schedule board• Schedule
• Capacity - Loaded/Total
• Cycle time performanceindicator
• Kanban quantity Overview
• Job status symbols legend
• Kanbans colored by lean schedule groups
Kanban board for process jobs • Job list/ Sequence
• Job details
• Instructions
• Picking list
• Pegged jobs (upstream)
• Barcode mode
• Barcode input
• Finished goods overview
• Material overview
Kanban board for transfer jobs • Job list/ Sequence
• Filter
• Job details
• Picking list
• Pegged jobs (upstream)
• Barcode mode
• Barcode input
• Kanban quantity overview
Lean primer Industry Summit
Lean primerLearn more on my blogManufacturing components Manufacturing process
AlexCar
AlexFrame
Floor
Roof
2 x Side
Engine
Transmission
Welding
Assembly
Painting
Runtime
Runtime
Queue time before
Runtime
Queue time after
Old LeanSetup Multisite, Items, Operations, Work cells, Work centers and Work center groups, BOMs, Routes
Creation and Estimation Kanban, Production order
Scheduling and ExecutionHeijunka board, Sales order, Lean order schedule, Production order
CostingProduction order
New LeanSetup Released products, Resources and Resources groups, BOMs, Production flow model and Production flows, Activities, Kanban rules
Creation Kanban
SchedulingKanban schedule board
ExecutionKanban board for Process jobs, Kanban board for Transfer jobs
CostingBackflush costing calculation, Production flow
New vs. Old Quick comparisonAX 2009 AX 2012
Manufacturing kanban Manufacturing kanban (Process activity)
Replenishment kanban Withdrawal kanban (Transfer activity)
Lean order schedule Sales event kanban
Drumbeat Throughput ratio
Work cell Work cell (Resources group)
Fixed kanban Fixed quantity kanban
Target kanban Minimum stock event kanban
PTO kanban Sales event, kanban line event kanban
Heijunka board Kanban schedule board
Manufacturing kanban board Kanban board for Process jobs
Replenishment kanban board Kanban board for Transfer jobs
Tips• Do not fall for the temptation of using only one activity and one location – this will make it impossible to filter (operational issues) and cause performance issues
• Implement flow: Keep material moving, reduce security buffers, kanban sizes and batch sizes
• Implement cellular manufacturing: Group resources to work cells, remove buffer space
• Optimize system performance and user satisfaction by only registering required data. Don’t register data because you might use it one day …
• One product can have multiple active kanban rules. For example, a fixed rule and an event rule for large sales orders
• Configure production flows and activities as versions
• Use product configuration in combination with sales event kanbans
• Remember implementing lean is not just an ERP exercise!
ResourcesLearn more on Information Sourcehttps://informationsource.dynamics.com Core concepts
(Business value, How-To, Design insights, Implementation considerations)RFP Q&AServicesAvailable for all users with Partner Source or Customer Source login
© 2012 Microsoft Corporation. All rights reserved. Microsoft, Windows, Windows Vista and other product names are or may be registered trademarks and/or trademarks in the U.S. and/or other countries.The information herein is for informational purposes only and represents the current view of Microsoft Corporation as of the date of this presentation. Because Microsoft must respond to changing market conditions, it should not be interpreted to be a commitment on the part of Microsoft, and Microsoft cannot guarantee the accuracy of any information provided after the date of this presentation. MICROSOFT MAKES NO WARRANTIES, EXPRESS, IMPLIED OR STATUTORY, AS TO THE INFORMATION IN THIS PRESENTATION.
Recommended