Chapter X. Electronic KANBAN (delivery KANBAN)

Transcription

1 Chapter X. Electronic KANBAN (delivery KANBAN) Table of Contents 4.1. General Information What is KANBAN? General information about delivery KANBAN Who has to use the tool and who will train this tool 4.2. General settings (contact person in Klingenberg) Setup Coverage Group for KANBAN Setup general KANBAN parameter 4.3. Initializing KANBAN process Settings for new KANBAN item Setup KANBAN box data Setup fields in item master Start Kanban process 4.4. KANBAN process Incoming KANBAN box Scanning boxes Overview of processed boxes (inbound) Refill empty KANBAN box Scanning boxes Overview of processed boxes (inbound) Information about box status Error messages 4.5. Recaculation Recalculation Internal KANBAN groups 4.6. KANBAN errors 1

2 Path: BaseLine 2006B / KANBAN Kanban Menu: Management console of the Kanban Process 2

3 4.1. General Information What is KANBAN? Target of using KANBAN is the reduction of inventory and also a reducing of money tied up in stocks. At the same time KANBAN increases the flexibility of verifying demands. Kanban is a self-controlling production method following the PULL principle where parts are got only as and when they are needed. The flow of information in this process is backward-bound (from the user to the manufacturer), while the flow of material is forward-bound (from the manufacturer to the user) General information about delivery KANBAN Electronic KANBAN Process KANBAN with Suppliers 1/1 Empty container is scanned in the warehouse of subsidiary (Italy) Automatic data transfer from Axapta into AS400 via B2B Store in warehouse Automatic generation of customer purchase order Shipment to subsidiary Removal from storage ( packed and labelled with KANBAN- Label ) OEM-Value-Chain / MA-LO, hw Druck- und Temperaturmesstechnik 3

4 KANBAN 2D Barcode Label Defined Barcode string (example): 0101CB#01L #07W052638# #031# #051# # 4

5 Description: Who has to use the tool and who will train this tool (contact person in Klingenberg) KANBAN is a tool for both, to help the logistics-department to group the items purchased and act according to the rule defined for each quadrant 5

6 during a Demand Segmentationn KAIZEN (=special work shops) and for management to get an overview of the inventory structure. With various KAIZENs in Klingenberg and the subsidiaries (only European subsidiaries at the moment) the tool is introduced. The whole process started in 2004 and will continue over the next years. During those KAIZEN the idea of this tool is explained in detail. Note This tool has only to be used after a Business KAIZEN with support from KAIZEN team Klingenberg. For details about the schedulee which subsidiary will be visited in near future please contact the KAIZEN office in Klingenberg. (Michael Richter) 4.2. General settings X.2.1. Setup Coverage Group for KANBAN 6

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9 Setup general KANBAN parameter Enter address for error message receiver Enter IP of SMTP Server 9

10 10 Create user with User Type Terminal

11 Create new terminal user in network KanbanUser Networkaccount Kanban Link Axapta account to this network account Handheld Axapta you need to login with this Terminal user! 4.3. Initializing KANBAN process Settings for new KANBAN item Setup KANBAN box data Select Item to use for Kanban 11

12 Insert one record per Box in the Form BaseLine/Kanban/Kanban Boxes Insert Box Id for selected Item Quantity will be entered by system (=multiple quantity in item master) Fields Purchase order, Delivery note and Kanban Status: see chapter 3.3) Information about Box Status Setup fields in item master Select Kanban Coverage group 12

13 Start Kanban process Select Kanban Coverage group Select primary vendor Make sure that all necessary price data is entered 13

14 Enter Refill Quantity for the Kanban Item Description of Kanban Fields: - Kanban type: W=Warehouse, P=Production - Kanban-Group: sorting- and filtering information (allows to calculate only certain values of a specific product area: i.e. all Items manufactured in one particular line) - Date of calculation: will be set with calculation process (see 4.1) - Date when Kanban was defined: Date of update the calculated data (will be set with calculation process, see 4.1) - Green/Yellow/Red current amount: amount of Kanban cards (will be set with 14

15 calculation process, see 4.1) - Calc Base: Flag on which usage the recalculation of the Kanban should be based on; 3, 6 or A for annually; pre-filled with A, once a Kanban-Flag is set 4.4. KANBAN process Create new PO, check all necessary data Select Kanban Item Select a Box Id that you defined in the Kanban Boxes Form for this Item, Kanban Type will then selected automatically 15

16 Post and send B2B order as usual -> this B2B order will be sent with the selected Kanban type flag 16

17 Incoming KANBAN box Start Handheld Axapta, you will get following screen: Current user Refill empty Box Scan arriving (full) Box Check if Box is Kanban or not Finish Handheld Axapta Scanning boxes Delivery note of current Record already posted? Information about latest Scanning Information for User Go back to Main Menu Post Delivery note of current record -> also possible to go on with scanning other boxes and post the Delivery notes later (see chapter 3.1.2) Overview of processed Boxes (Inbound) ) 17

18 If you post immediately: If successfully posted As long as this form is active you are able to scan incoming Boxes. You will get an error if you try to scan a box twice: 18

19 Overview of processed boxes (inbound) Data about scan process: - when - who - scanned Barcode string If current record not yet posted in Handheld Axapta (Flag Posted not set) If there is an error occurred during Kanban scan process Fields: - Posted: set if Delivery note has been posted - Purchase Order: Purchase order of incoming box - Status: Status of Purchase order - Packing Nr: Packing number if there is one in Bare code - Line No: Line No of PO -> there is always one - Item number: Item of scanned Box - Quantity: Quantity of scanned Box - Kanban Box Id: Box Id of scanned Box Error description: Use this to solve the problem in the Standard Purchase Order Form manually After solving the problem, deselect this flag -> error icon in the Grid will disappear 19

20 and a warning icon will appear: error solved When problem is solved and purchase order is posted by standard functionality -> system will automatically update the data (set flags/po number) in form Inbound Kanban Refill empty KANBAN box Scanning boxes As long as this form is active you are able to scan empty Boxes. You will get an error if you try to scan a box twice. Scan Field Information about latest Scanning Information for User Go back to Main Menu 20

21 Process is running Information of scanned box: Overview of processed boxes (outbound) All outgoing Kanban data is saved here: Data about scan process: - when - who - scanned Barcode string If there is an error occurred during Kanban scan process 21

22 Fields: - PO created, Posted, XML sent: set if Purchase Order has been created/posted/sent - Old Purchase Order: Po number of scanned empty box - Purchase Order: new created Purchase order that is sent - Status: Status of new Purchase order - Line No: Line No of new PO -> there is always one - Item number: Item of scanned Box - Kanban Box Id: Box Id of scanned Box - Quantity: Quantity of scanned Box After solving the problem, deselect this flag -> error icon in the Grid will disappear Error description: Use this to solve the problem in the Standard Purchase Order Form manually and a warning icon will appear: error solved When problem is solved and purchase order is posted by standard functionality -> system will automatically update the data (set flags/po number) in form Outbound Kanban. 22

23 Information about box status In the Form Kanban Boxes you can see the current status of all defined boxes: Kanban defined Items Current Status of Box In which Purchase Order is this item currently used Delivery note of current Purchase order if packing slip already posted 23

24 Error messages When occurring an error that aborts the scan process (create order / post / send), an error mail is sent to responsible person -> has to solve in PO form 24

25 4.5. Recaculation Recalculation Recalculation Form is a utility to recalculate the Kanban sizes. Open Kanban Recalculation Form Filter all Kanban items that have increasing or decreasing change of usage to last year Update leadtime of all selected items in item master Do the calculation of sizing of all Kanban items Update calculation to selected or to all items 25

26 The recalculation is done in following steps: 1. Mark all records you want to be recalculated 2. Push button Calculation to recalculate the values -> the calculated results are shown in the fields Recalc (next to the regarding field current amount of boxes ) 3. Push button Update -> Update selection / all to write the recalculated values into current amount fields of selected / all records In case of any change to quantity of boxes: current date will be set in field Date when the Kanban was defined Description of Fields: Out of Item master: - Kanban type - Kanban Group - Item number - Item name - Vendor: primary vendor - Calculation base - Multiple: multiple order quantity - Min. order quantity - Lead time: Purchase / Stock / Sales - Quatrant: I,II, II, IV, V - Diversity factor - XYZ Classification 26

27 Recalculation: - Date of Calculation: date when the calculation of 12, 6 and 3 month avg. was done - Ø monthly Usage last 12, 6, 3 Month - Ø usage/ box - % special Kanban last 3 Month (= extra Kanban order for peak -> indicates if Kanban is to small) - Date when Kanban was defined: date of data update (set current amount to calculated amount) - Current amount of green/yellow/red boxes: amount of boxes in each category (either manually entered or calculated via Calculation -button) - Recalculated amount of green/yellow/red boxes Internal KANBAN groups Define different Kanban groups. Group the items to do evaluation of kanban data 27

28 4.6. KANBAN errors 28

29 4. 7 AS400 settings COS5Y0 B2B incoming post box E then Enter then F5 : 29

30 WBC700 dispatch Needed for correct picking process written by: M. Richter, GB PI-KPO 30