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Object documentation Control Cycle for Classic Kanban 

Definition

A control cycle defines the relationship between the demand source (such as a production line in production) and the supply source (such as an external supplier or warehouse). You enter the appropriate parameters for classic kanban.

Structure

You can define the following parameters:

Kanbans Box

Kanban Circulation

For kanban circulation you need to define the following:

  The number of kanbans that circulate between the supply source and the demand source

  The material quantity per kanban

The number of kanbans as well as the kanban quantity is based on the following criteria:

  Average consumption

  Replenishment lead time of a kanban

  Fluctuations in consumption and in the replenishment lead time

This is represented in the following formulas:

(Number of containers – 1) x contents of containers = consumption in replenishment lead time of a container

Number of containers = ([consumption/time unit) x replenishment lead time container]/contents of container) +1

Maximum Number of Empty Containers

You can enter a limit that specifies the maximum number of containers that are allowed to be empty at one time for the supply source view of the kanban board. This limit is only used for information purposes and evaluation. If the number of empty containers exceeds this limit, the system displays a red traffic light in the line of the appropriate control cycle in the supply source view of the kanban board. For this to happen, you must select the Display Signal field under Settings Control Cycle Display.

Replenishment Strategy

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Nacschubstrategie

In the control cycle you define how replenishment between the supply source and the demand source is to be organized. For more information, see Definition of Replenishment Strategy in Control Cycle.

Process Control

Separating the Goods Receipt from the Status Change and Independent Supply Source

You can also control the separation of goods receipts from the status change by flagging the Separate Goods Receipt field. For more information, see Separation of Status Change and Goods Receipts Posting. You can define whether the source defines the time of the replenishment in the Independent Source field. For more information, see Independent Source/Separation of Status Change and Replenishment.

Status Sequence

You can assign a status sequence to the control cycle in the Status sequence field. This defines the order in which the statuses are set. It also specifies whether certain statuses are mandatory, whether some are optional, or whether some statuses are not allowed. For example, you can define that the statuses, In Process and In Transit have to be set one after the other, but that the status In Use is not allowed. You define the status sequence in Kanban Customizing. For more information about statuses, see Status Change/Kanban Signal and Status Sequence.

One-Card KANBAN

In the one-card KANBAN system, you must define a special logic for triggering the kanban signal. These logics are defined in the field Trigger replenishment. For more information, see One-Card Kanban and One-Card Kanban/Using a Special Logic for Triggering the Kanban Signal. If you do not want the system to trigger replenishment until a trigger quantity has been reached, you must enter the value 3 in the Trigger Replenishment field and enter this quantity in the Trigger Quantity field.

Packing Instructions

Packing instructions are integrated in the kanban process. If you want to use this function, in Customizing for the replenishment strategy, you have to define whether the packing instruction is only for information purposes or whether it is also used for controlling. You can only enter packing instructions containing one material. This means that only one material can be packed in the packing instruction used. However, multi-level packing instructions are permitted.

If you use packing instructions, the procurement quantities of the kanbans are not entered in the control cycle but are calculated using the cumulated quantity or total quantity of the material from the packing instruction. In the control cycle you can only enter the number of load carriers you want to request per JIT call. The main load carrier of the packing instruction is copied to the Load Carrier field and cannot be changed.

Note

Note that you can only withdraw stock from the warehouse according to a packing instruction if you work with the replenishment strategy 6 Transfer Requirements from WM-Managed Storage Location. For this replenishment strategy, the packing instruction has a controlling function when withdrawing stock. For all the other replenishment strategies, it is only used for information. For more information, see Replenishment from WM-Managed Storage Locations.

The following table describes the effects of the setting in Customizing for the replenishment strategy on the fields Quantity and Number of load carriers in the control cycle.

Setting in Customizing for the Replenishment Strategy

Quantity

Number of Kanbans in Control Cycle

No functional use, packing instruction acts as commentary

Quantity is entered in the control cycle; fixed quantity and rounding quantity are referred to when kanban is created.

Field is empty, entries here have no functional effect

Kanban quantity from instructions; several load carriers possible per kanban

Quantity is entered in the packing instruction.

Fixed quantity and rounding quantity not taken into account.

Change in quantity in the packing instruction leads to a change in the quantity in the control cycle; quantity of the kanban is distributed over the given number of load carriers.

Kanban quantity from packing instructions; always one load carrier per kanban

Quantity is entered in the packing instruction.

Fixed quantity and rounding quantity not taken into account.

Is always 1 since a kanban always corresponds to a load carrier.

 

Automatic Kanban Calculation

You can also use the functions available in the automatic kanban calculation to determine the number of kanbans or the kanban quantity. For more information, see Definition of Automatic Kanban Calculation in Control Cycle.

Print Control

You define whether or not the kanbans are to be printed and which event is to trigger the printout. You also specify the output device. For more information, see Printing and Circulation of Kanbans.

Additional Data

Ship-to Address

If you want the delivery to be made directly to the production line, you can specify a precise delivery address indicating the supply area data. To do this select Goto Delivery address.

The plant address is already complete. Here, you can also enter the information required for the supply area.

Locking and Deleting Kanbans

If necessary, you can delete or lock kanbans in the control cycle. You lock a kanban, for example, if it is not to be used for a certain length of time as consumption within the control cycle has fallen. If the status of a locked kanban is set to Empty, the system automatically changes the status to Wait. A locked kanban cannot be replenished.

You can only delete a kanban if it has no further replenishment elements for which a goods receipt still has to be posted, that is, when the kanban status is Wait. All kanbans that do not have the status Wait must be locked before they can be deleted.

Proceed as follows:

  1.  Choose GotoKanban.

A dialog box appears displaying the following information:

  Kanban number

  Actual quantity

  Kanban status

  Date and time of the last status change

  2.  To lock kanbans, select the checkbox of the appropriate kanban(s) in the Lock column.

  3.  To delete kanbans, select the checkbox of the appropriate kanban(s) in the Delete column.

 

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