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Kanban in SAP
Topics
What is Pull and when do I use it
Kanban Calculator
SAP reports
Fields
3
Purchase Pull System
• Pull systems establish strategically located “buffers” of parts within a process.
• Inventory (or part) replenishment is “triggered” based on consumption versus
pushed based on net requirements.
Consumption
Manufacturing
Supplier
4
Pull System Design Drivers
• Pull is about
– Set Up
– Maintenance
• Demand is dynamic and changes over time
– Seasonality, ramp up/down, engineering changes, etc. drive need to resize Kanban
quantities
– Need to review Kanban sizes at least quarterly
Goal
1. Establish
2. Stabilize 3. Reduce
inventory control
process inventory
(Kanban sizing)
5
Effectiveness, then efficiency
Kanban
6
Coefficient of Variation?
• Coefficient of Variation (CoV) measures the variability of demand
– It is defined as the ratio of the standard deviation (σ) to the mean (μ)
Additional Data
Push Pull
Required
7
CoV Example
Weeks Demand
A B C
• Parts A and B
1 25 30 0 meet the rule of
2
3
25
25
40
40
0
0
thumb COV<=1
4 25 30 0 • Part C has same
5 25 30 0
6 25 70 150 average
7 25 0 0 demand, but
8 25 0 0
9 25 0 0
high variability
10 25 0 0
11 25 60 0
12 25 0 150
Mean (Average) 25 25 25
Standard Deviation
0.0 25.0 58.4
(Variation)
CoV 0.0 1.0 2.3
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CoV alone does not always
indicate a good candidate for
pull
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The Run Ratio
Weeks Demand
1 25
A B
30 0
C
• The Proportion of Time a
2
3
25
25
40
40
0
0
Part is Used or Sold
4 25 30 0 – A: 12/12=100%
5 25 30 0
6 25 70 150 – B: 7/12=58%
7 25 0 0
– C: 2/12=17%
8 25 0 0
9 25 0 0
10 25 0 0
11 25 60 0
12 25 0 150
Mean (Average) 25 25 25
Standard
Deviation 0.0 25.0 58.4
(Variation)
CoV 0.0 1.0 2.3
Run Ratio 100% 58% 17%
10
Frequency of Demand
Kanban Calculator
11
Kanban Calculator
Helps determine good candidates for Pull
–Performs all of the calculations automatically
–Compares current situation vs. expected if part is converted to pull
12
Calculator Transactions
ZMMR is the first transaction that is
ZMMR run. This transaction gives us the
Usage data for the materials.
ZMEV is the second transaction that
is run. This transaction gives us the
ZMEV
master data for the materials.
ZPIRN is the third transaction that is
run. This transaction gives us the
ZPIRN Supplier for the materials.
14
Kanban
Kanban
Internal External
Works with Production Orders
Works with purchased parts,
for internally procured material
auto-generating PO’s,
between workcenters at a plant.
and vendor replenishment.
Regular Consignment
Inventory Inventory
15
SAP eKanban Master Data
• Supply Area
– Person Responsible
– Storage Location
• Control Cycle
– Number of Bins
– Bin Quantity
– Replenishment Strategy
• In house Production
• External Source
• Stock Transfer
• Kanban Specific Vendor (if the vendor has multiple Ordering addresses)
– New Info Record
16
SAP eKanban External Procurement
17
Step 1: Create Supply Area PK05
18
Step 1: Create Supply Area PK05
19
Step 1: Create Supply Area PK05
Step 1
Enter the Supply
Area and description
Step 2
Click drop down
for Storage Location be
sure to choose the proper
area (thus must be an IM
location)
Step 3
Click drop down and
select corresponding MRP
controller
20 code of the area
EP Step 2: Alter Material Master
21
EP Step 2: Alter Material Master
Select “MRP1” tab
22
EP Step 2: Alter Material Master
Select “MRP 2” tab
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EP Step 2: Alter Material Master
In the “MRP 4” tab
click
“Organizational
Levels”
Key in the IM
storage location
you wish the
items to drop into
once received
24
EP Step 2: Alter Material Master
Change this Field to 1
(must be excluded
from MRP) and save.
25
EP Step 3: Enter Materials PK01
26
EP Step 3: Enter Materials PK01
27
EP Step 3: Enter Materials PK01
28
EP Step 3: Enter Materials PK01
Enter Vendor #
Leave Agreement field
blank unless using
Scheduling Agreement,
29 then fill in Agreement #
and Line #
EP Step 3: Enter Materials PK01
Kanban Indicator
must be marked
“X” for Sch.
Agreements at the
Line Item level
30
EP Step 4: Managing the eKanban board
Enter transaction to
view kanban Bin status
and to process Kanban
order.
31
EP Step 4: Managing the eKanban board
32
EP Step 4: Managing the eKanban board
In this view you can see the status of Bins in the Supply Area. This is where the
operators can Empty the Bin in order to create a Purchase order to replenish
stocking level of the Bin. The initial status of the Bin is Wait”. There are several
statuses that can be set. Check the legend to see. To set the Bin empty, Select
both
33 bins and click the “To Empty” button. Multiple Bins can be emptied at the
same time.
EP Step 4: Managing the eKanban board
When a Kanban Bin is emptied the Bin icon will turn red.
A Purchase order will automatically be released.
34
EP Step 4: Managing the eKanban board
To change a Bin status to anything other than empty or full, Right click on a Bin
and select “Kanban correction.”
35
EP Step 6: Managing the eKanban board
Double click a line. Select the desired status. If you are keying it to full, enter a
36 qty. Once complete, select the “Status/qty” button.
EP Step 6: Managing the eKanban board
To set to the “Full” Status manually, select a bin and click “To Full”. This will
make a FULL MIGO_GR! So be careful. Also, the bin will automatically be set to
37 Full once any partial/full Migo_GR has been posted against the PO.
EP Step 4: Managing the eKanban board
To get any information about the bin, double-click on a bin. The PO can be
altered by clicking the Replenishment button. The PO is also displayed here.
38 The time the Bin status was changed is displayed in EST.
Triggering Kanban in SAP
39
SAP Kanban - Demand View
SAP Transaction: PK13N
Green Bin (FULL) = Bin is full or being used currently in production
Red Bin (EMPTY) = Bin is empty (on order)
Purple (WAIT) = Temporary status
40
Kanban RF Process
1. When a Kanban Bin is Empty, 2. Flip the Status Card to “On
Scan the Barcode Card for the Empty Order”
Bin
BIN 1 BIN 2
BIN EMPTY
41
SAP RF Menu
Using the RF Tablet, Select 6 3 1
42
Reorder Point/Min. Max.
• The reorder point ("ROP") is the level of inventory when a fresh
order should be made with suppliers to bring the inventory up
to a fixed level or by a fixed quantity.
43
Settings
Maximum Stock Level Fixed Order Quantity
• MRP Type = “ZR” • MRP Type = “ZR”
• Lot Size Key = “HB” – Replenish to the • Lot Size Key = “FX” – Fixed Order Quantity
maximum stock level • Fixed Lot Size: This is a required entry. It
• Maximum Stock Level: This is a required entry. denotes the quantity that will be procured in
It denotes the quantity of stock that may not the event of a shortage.
be exceeded • If the amount of the shortage is less than the
• It calculates the Lot size using the following fixed lot size, it is the fixed lot size that is
two Formulas and creates an order proposal procured (and not the lesser quantity that is
using the greater of the two lot sizes calculated actually required).
• If the amount of the shortage is greater than
the fixed lot size, a multiple of the fixed lot
size is procured. The system creates several
purchase order proposals for this purpose.
44
Kanban vs. Reorder Point
Kanban
Reorder Point
45
Questions
46