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8/12/2019 Kanban Procedure India
http://slidepdf.com/reader/full/kanban-procedure-india 1/6
KANBAN PROCESSES , PROCEDURES AND PRE-REQUISITES
1. Stock transfer from Main Stores to Production Line
Basic rules and Prerequisites:
• MRP type must remain as it has been like “PD” or “VB” or any active MRP type.
• Backflush indicator is must. It can be defined in the Routing of the header item (assembly). If
Backflush indicator is set for kanban material in the Routing of the assembly, then this material
will be backflushed in all the production orders for that assembly in the relevant plant (Material
issue through Pick List not required against production order). Backflush Materials do not
appear in the Pick List.
• 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• 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.
• KN01 - Kanban Storage Location stock is excluded from MRP by default. This indicator
shall be removed in MRP4 view of material master. Removing this indicator will enable MRP
run for generating PR from dependent and independent requirements to enable procurement
from vendors into the main stores.
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).
Go to last page of this document for detailed explanation on business process procedures.
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2. External procurement from Vendor to Main Stores
Basic rules and Prerequisites:
• MRP type should be ‘ND’ in MRP1 view of material master.
• Availability check should be “KP” in MRP3 view of material master.
• Material received from vendor is directly posted to unrestricted stock. Inspection at vendors
place or vendor’s process control to ensure rejection free material. Inspection set up in Material
master should be inactive.
• Backflush is not required and Material is issued against a Pick List for Production Order.
• Storage location exclusion is automatic for storage location KN01. If receiving storage
location is other than KN01, Indicator for storage location in MRP4 should be filled with 1.
Process steps:
1.
E-mail address in Vendor Master is mandatory2. Create supply area for Main stores. TC: PK05
3. If required, extend the material to main storage location. TC: MMSC
4. Make the necessary changes in the material master as explained above.
5. Create scheduling agreement. Put kanban indicator (X) in the additional data
of item.
6. Create Kanban control cycle. TC:PKMC
7. Print the barcode. TC:PK17
8. 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.
9. View the demand source view. TC: PK13n
10. When the material is received at Gate, perform goods receipt into blockedstock (movement type 103). TC: MIGO
11. Once the material reaches Main stores scan the barcode to FULL. TC: PKBC
(At the background GR with 105 movement will happen).
Go to last page of this document for detailed explanation on business process procedures.
3. External procurement from Vendor directly to shop
Basic rules and Prerequisites:
• MRP type should be ‘ND’ in MRP1 view of material master.
• Availability check should be “KP” in MRP3 view of material master.
• Backflush indicator is must. It can be defined in the Routing of the header item (assembly). If
Backflush indicator is set for kanban material in the Routing of the assembly, then this material
will be backflushed in all the production orders for that assembly in the relevant plant (Material
issue through Pick List not required against production order). Backflush Materials do not
appear in the Pick List.
• Confirmation should be done for each operation in the production order either individually
(CO11N) or collectively (CO15). Confirmation posts goods issue of components (relevant toconfirmed operation/s) to production order
8/12/2019 Kanban Procedure India
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• 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.
• Storage location exclusion is automatic for storage location KN01. If receiving storage
location is other than KN01, Indicator for storage location in MRP4 should be filled with 1.
• Material received from vendor is directly posted to unrestricted stock. Inspection at vendorsplace or vendor’s process control to ensure rejection free material. Inspection set up in Material
master should be inactive.
Process steps:
1. E-mail address in Vendor Master is mandatory
2. Create supply area for kanban stores (KN01). TC: PK05
3. Extend the material to Kanban storage location. TC: MMSC
4. Make the necessary changes in the material master as explained above.
5. Create scheduling agreement. Put kanban indicator (X) in the additional data
of item.
6. Create Kanban control cycle. TC:PKMC
7. Print the barcode. TC:PK17
8. 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.
9. View the demand source view. TC: PK13n
10. When the material is received at Gate, perform goods receipt into blocked
stock (movement type 103). TC: MIGO
11. Once the material reaches shop, scan the barcode to FULL. TC: PKBC (At the
background GR with 105 movement will happen).
Go to last page of this document for detailed explanation on business process procedures.
4. In house production (Between one sub-assembly line to Main assembly)
Basic rules and Prerequisites:
• MRP type should be ‘ND’ in MRP1 view of material master.
• Availability check should be “KP” in MRP3 view of material master.
• Backflush indicator is must. It can be defined in the Routing of the header item (assembly). If
Backflush indicator is set for kanban material in the Routing of the assembly, then this materialwill be backflushed in all the production orders for that assembly in the relevant plant (Material
issue through Pick List not required against production order). Backflush Materials do not
appear in the Pick List.
• 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
• Maintain KN01 storage location in the field - production storage location of MRP2 view in
the material master.
• Maintain ‘Kanban Production schedule profile’ in Work scheduling view of the material
master.• Material should have a valid BOM & Routing.
• All components for the assembly should be planned on Consumption based planning (VB) or
they should also be kanban item.(MRP type of child item should NOT be PD).
8/12/2019 Kanban Procedure India
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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).
Go to last page of this document for detailed explanation on business process procedures.
IMPORTANT POINTS TO NOTE
Schedule Agreement line items shall be checked for Tax codes, Excise Conditions
as a one time activity. Required corrections should be carried out when you get
error message that excise posting could not be carried out automatically. You
should also get the excise entries posted by competent personnel.
Confirmation of Production Orders is mandatory. You can do this thru’ Tcode
CO11N or CO15. This process triggers posting consumption of kanban
components thru’ Backflush.
In case you did not have sufficient stock of any Backflush item in stock for
consumption at the time of confirmation, but need to continue and make goods
receipt for Production order, you must later on process goods issue of Backflush
items so missed out, in Tcode COGI (select storage location KN01 and execute to
get list of items for which issue is pending) and post goods issues and save. This will
issue the pending components. Execute the report once again to ensure nothing is
left over before TECOing the orders.
Kanban Database Report is available in Tcode ZPKL. You can generate specific
list based on various selection parameters available.
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SAP MAIL THRU’ KANBAN WORKFLOW
Please note that the following roles and its related Kanban mail notifications:
INDMM_MM_JOB_PURCHASER_INAV (select your plant)
If you have this role, copy of mail to the vendor will be received in your SAP mail box.
Also, you will receive a mail alert when Schedule Agreement validity has expired
either for date or quantity.
INDPPPP_JOB_PRODCTN_SUPE_INAV (select your plant)
When a kanban production order is generated automatically, an SAP mail will be
received by you.
INDMMMM_JOB_INVENTORY_CL_INAV (select your plant)
If you have this role, you will receive mail notification in SAP mail box for
transferring material against a kanban reservation.
INDPPPP_JOB_MRP_CONTROLE_INAV (select your plant)
If you have this role, a mail alert will be sent to you, when Schedule Agreement
validity has expired either for date or quantity.
List of Role Authorization required for carrying out Kanban Transactions
in SAP.
INDPPPP_JOB_MRP_CONTROLE_INAV (Select your plant in place of INAV)
INDPPPP_JOB_MST_PRD_SCHL_INAV (Select your plant in place of INAV)
INDPPPP_PRODUCTN_OPERATO_INAV (Select your plant in place of INAV)
INDPPPP_JOB_PRODCTN_SUPE_INAV (Select your plant in place of INAV)
INDMMMM_JOB_INVENTORY_CL_INAV (Select your plant in place of INAV)
If you have authorization for one of these roles, you will be able to transact on Kanban
in SAP.
Please ensure that at least one relevant authorization from the above roles is availablebefore you start Kanban transactions in SAP.
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KANBAN BUSINESS PROCESS PROCEDURE
Business Process Business Process Procedure
Create Supply Area
(Tcode: PK05)Sre_BPP_05_PP01_PK05_Maintain Supply
Create Control Cycle
(Tcode: PKMC)Sre_BPP_05_PP01_PKMC_Crt_Cntrl Cycle
Sre_BPP_05_PP02_PKMC_Crt Cntrl Cycle_
Sre_BPP_05_PP0_PKMC_Crt Cntrl Cycle_
Sre_BPP_05_PP0!_PKMC_Crt Cntrl CycleC
Sre_BPP_05_PP05_PKMC_Crt Cntrl Cycle_
Sre_BPP_05_PP0%_PKMC_Crt Cntrl Cycle_
Sre_BPP_05_PP0'_PKMC_Crt Cntrl Cycle_
Kanban Transaction through Scanning or
Manual operation.
(Tcode: PKBC) Sre_BPP_05_PP01_PKBC_ScanE)pty*ull.
Event Driven Kanban – Requirement
generation.
(Tcode: PK23) Sre_BPP_05_PP01_P
K2_+enerateKan,a Goods Receipt – India Specific Process
(Tcode: PKBC)/_Sre_BPP_05_PP01_PKBC_ScanE)pty*
Kanban Board – Demand Source view
(Tcode: PK13N)Sre_BPP_05_PP01_PK1/_-e)andSource
Kanban Board – Supply Source view
(Tcode: PK12N)Sre_BPP_05_PP01_P
K12/_SupplySourceK Kanban Evaluation
(Tcode: PK18)Sre_BPP__PP01_PK1_CC_Kan,an_E$a
Kanban Correction
(Tcode: PK50)Sre_BPP__PP01_PK50_Kan,anErrorPro
Kanban Locking & Deleting
(Tcode: PKMC)PP_PKMC_Kan,an&o
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