One-Card KANBAN
Use
The purpose of this process, amongst other things, is to create a one-card KANBAN system with two kanbans in a control cycle. As a kanban is set to the status WAIT for certain periods in a control cycle, you can further reduce the inventory level at the demand source - especially during periods when the material is not required. In this procedure, replenishment is always triggered when the kanban that is currently being emptied is approximately half empty. The new kanban is then delivered before the current kanban is completely empty. This logic is illustrated in the following graphic:
To be able to guarantee the replenishment of the kanban currently in use, two kanbans are active some of the time in the one-card system. Therefore, this logic requires the use of two kanbans in the system.
Integration
In the one-card KANBAN procedure, you can also use all the functions available in the KANBAN module.
Prerequisites
Before you can use this procedure, you must select one of the processes in the field, Trigger replenishment when maintaining the control cycle.
Features
After the first container is reported full, the system proceeds as follows: The second kanban is set to the status WAIT. If a new kanban is requested, the system sets the full kanban to the status IN USE. With this status change the kanban with status WAIT is automatically changed to status EMPTY and thus replenishment is triggered. When this new kanban is delivered, it receives the status FULL. As soon as the kanban from which material is still being withdrawn is set to EMPTY, the system automatically sets it to status WAIT and the process is repeated.
This procedure is illustrated in the following graphic:
After the first container is reported full, the system proceeds as follows: When a new kanban is requested, the full kanban is set to status EMPTY. With this status change the kanban with status WAIT is automatically changed to status EMPTY and thus replenishment is triggered. The kanban from which material is still being withdrawn receives the status WAIT. When the new kanban is delivered, it receives the status FULL and the process is repeated. As opposed to the logic with the status IN USE, you do not have to work with an additional status here. On the other hand, you have no possibility in the system of seeing whether a container is currently being emptied.
This procedure is illustrated in the following graphic:
The procedure here is similar to the two procedures described above. However, the difference here is that the kanban is set to EMPTY when the remaining quantity in the kanban reaches or exceeds the trigger quantity. In this process, the parts are withdrawn with the quantity signal. In this case, you must maintain the trigger quantity as well as the logic in the control cycle. This process is particularly useful for parts that are not used on a regular basis. Therefore, you can procure parts with KANBAN without having to keep several containers in stock. However, a PDC system is required for this procedure.