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Background documentation Lean Manufacturing, MRP Evaluation  Locate the document in its SAP Library structure

Technical Data

Technical Name of Business Function

LOG_PP_LMAN

Type of Business Function

Enterprise Business Function

Available From

SAP ERP Enhancement Package  2005.2

Technical Usage

Central applications

ECC Application Component

Production Planning and Control (PP)

Supplementary Constituents in Further SAP Applications

SAP Auto-ID Infastructure AII 5.1, SAP NetWeaver 7.0 BI Content Add-On 3

Business Function Requiring Activation in Addition

Not relevant

Use

You can use this business function to further optimize your production and material procurement according to the principles of lean manufacturing. You are provided with further support for the control and monitoring of your Kanban processes and are able to smooth production in repetitive manufacturing according to the "Heijunka" method.

Using this business function, the MRP controllers are able to gain flexible cross-plant and cross-material overviews of the current stock/requirements situation in a simpler manner.

The new functions result in greater flexibility, lower stocks (WIP), a higher degree of transparency, and more even production.

Integration

The existing Kanban solution has been enhanced. Among other things, the prerequisites to enable Kanban processes to be operated on the basis of RFID technology if the component SAP Auto-ID Infastructure (SAP AII) 5.1 is used have been established. This business function also provides data extractors for enhanced Kanban evaluations in SAP NetWeaver 7.0 BI Content Add-On 3.

The new functions for production smoothing are based on the revised and enhanced sequencing functionality within repetitive manufacturing.

The new options for representing material groupings are integrated in the stock/requirements list within material requirements planning (MRP) and long-term planning.

Prerequisites

You activate the new options in Customizing or within the applications themselves.

You have installed the following components as of the version mentioned:

 

Type of Component

Component

Required for the Following Features Only

Software component

SAP-APPL

 

Technical component or business content, e.g. Portal Content

Not relevant

 

 

Features

Kanban Solution: New Aspects

●      The new tabular representation of the kanban board facilitates kanban evaluation and control on an even more flexible basis. The users have intuitive and extensive personalization options. The Business Add-Ins for Kanban enable you to adjust the representation to additional requirements of your business processes with a minimum of effort.

Kanban Board (Tabular Representation)

●      You can use the automatic updating of the kanban board to automatically represent the current situation regarding the kanban control cycles graphically or in tabular form on monitors (such as at the manufacturing center, in goods receiving, or in the warehouse), for example.

Kanban Board (Tabular Representation)

Kanban Board (Graphical Representation)

●      The new replenishment strategy Kanban with Reporting Point Confirmation for repetitive manufacturing enables you to control the production steps for a material between multiple processing stations (reporting points) of a line with system support via Kanban.

Replenishment Strategy with Reporting Points

●      Delayed replenishment elements in Kanban are determined and shown in a new list. You have the option of assigning particularly critical delays as alert information (for example, in the form of a text message or an e-mail) to recipients on a rule basis and sending this information accordingly.

Invoke Delayed Replenishment Elements

●      You can use SAP Alert Management in the Kanban process to be able to respond quickly and effectively to critical situations.

Activation of Kanban Alerts

●      New BAPIs for Kanban support you in realizing your own scenarios and interfaces for the management of control cycles and kanbans:

○       BAPI_KANBANCC_GETLIST_ALL

BAPI to read control cycle data from the database.

○       BAPI_KANBAN_GETLIST_ALL

BAPI to read data on a kanban from the database.

○       BAPI_KANBANCC_EXISTCHECK

BAPI to check the existence of a control cycle.

○       BAPI_KANBANCC_CREATE

BAPI to create a control cycle.

○       BAPI_KANBANCC_CHANGE

BAPI to change a control cycle.

○       BAPI_KANBAN_CHANGE

BAPI to change a kanban.

○       BAPI_KANBANCC_DELETE

BAPI to delete a control cycle.

●      RFID-supported Kanban integrates the RFID technology into Kanban processing. You can monitor the movements and statuses of a kanban container using RFID transponders and devices. RFID-enabled Kanban makes the Kanban process more transparent and gives you a better overview of your stock situation. A prerequisite is the use of SAP Auto-ID Infrastructure (SAP AII) 5.1.

RFID-Enabled Kanban

●      New data extractors for Kanban key figures in SAP BI are available enabling you to analyze the Kanban processes in SAP BI with SAP NetWeaver 7.0 BI Content Add-On 3.

For more information on Kanban key figures, refer to the BI documentation on Kanban key figures in the SAP Library for SAP NetWeaver under SAP NetWeaver Library → SAP NetWeaver by Key Capability→ Information Integration by Key Capability → BI Content → Supply Chain Management → Manufacturing.

●      The automatic setting of the kanban status ‘In Transit’ supports the integration of the Kanban process between the Enterprise Resource Planning (ERP) system and the Supplier Network Collaboration (SNC) system. When the vendor sends a shipping notification, the status of the corresponding kanban container in the ERP system is automatically changed to 'In Transit', just as in the SNC system.

For more information on the integration of Kanban in the SNC system, refer to the SAP Service Marketplace under Education, Consulting, Solutions Areas and More/SAP Solutions. Choose Industry Solution Sets → SAP for Automotive → Media Library → Supply Network Collaboration.

Production Smoothing and Sequencing in Repetitive Manufacturing

●      In the Heijunka process, a new procedure for production smoothing (leveling) is available to you in the Sequencing functionality in Repetitive Manufacturing.

Production Smoothing (Heijunka) in the SAP-System

●      In addition to other improvements in user friendliness and the functionality a separate transaction has been realized enabling you to change the sequence schedule interactively.

Change Sequence Schedule Interactively

●      You can specify a planning profile and a visualization profile on the initial screen for Sequencing. The visualization profile in Sequencing facilitates the automatic refreshing of the representation, the display of the current timespot, and the definition of plant-specific default profiles.

Changing the Visualization Profile

●      The Integration of Kanban in the Heijunka process enables the system-supported, straightforward combination of the Heijunka process for production smoothing with Kanban-controlled repetitive manufacturing.

Kanban in the Heijunka Process

●      With the Business Add-In for Sequencing, you can specify your own scheduling sequence for the planned orders in sequencing.

Sequence Planning

New Features in the Evaluations for MRP and Long-Term Planning

In addition to the conventional individual material view, you can use the integrated planning situation of several materials as a material grouping in the stock/requirements list. With regard to the selection of a material grouping, you have the following options:

●      Product groups

●      Cross-plant material grouping

●      APO supersession chains

●      Material grouping defined on a customer-specific basis

See Display of Material Groupings

 

 

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