kanban procedure india

8/12/2019 Kanban Procedure India

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KANBAN PROCESSES , PROCEDURES AND PRE-REQUISITES

1. Stock transfer from Main Stores to Production Line

Basic rules and Prerequisites:

• MRP type must remain as it has been like “PD” or “VB” or any active MRP type.

• Backflush indicator is must. It can be defined in the Routing of the header item (assembly). If

Backflush indicator is set for kanban material in the Routing of the assembly, then this material

will be backflushed in all the production orders for that assembly in the relevant plant (Material

issue through Pick List not required against production order). Backflush Materials do not

appear in the Pick List.

• Confirmation should be done for each operation in the production order either individually

(CO11N) or collectively (CO15). Confirmation posts goods issue of components (relevant to

confirmed operation/s) to production order• Maintain KN01 storage location in the field in Production Storage Location of MRP2 view in

the material master. Back flushing will take place from this location. Field - Storage location

for external procurement (EP) should be MN01 (Main Stores) in the material master.

• KN01 - Kanban Storage Location stock is excluded from MRP by default. This indicator

shall be removed in MRP4 view of material master. Removing this indicator will enable MRP

run for generating PR from dependent and independent requirements to enable procurement

from vendors into the main stores.

Process steps:

1. Create supply area for Kanban storage location (KN01). TC: PK05 2. Extend the material to Kanban storage location. TC: MMSC

3. Make the necessary changes in the material master as explained above.

4. Create Kanban control cycle. TC:PKMC

5. Print the barcode. TC:PK17

6. Set the kanban status to EMPTY by scanning the barcode. TC: PKBC. A

material reservation will be created for stock transfer from main stores to

KN01.

7. View the demand source view. TC: PK13n

8. Once the Main stores sends the material to shop floor scan the barcode to

FULL. TC: PKBC (At the background stock transfer with 311 movement will

happen).

Go to last page of this document for detailed explanation on business process procedures.



2. External procurement from Vendor to Main Stores


• MRP type should be ‘ND’ in MRP1 view of material master.

• Availability check should be “KP” in MRP3 view of material master.

• Material received from vendor is directly posted to unrestricted stock. Inspection at vendors

place or vendor’s process control to ensure rejection free material. Inspection set up in Material

master should be inactive.

• Backflush is not required and Material is issued against a Pick List for Production Order.

• Storage location exclusion is automatic for storage location KN01. If receiving storage

location is other than KN01, Indicator for storage location in MRP4 should be filled with 1.

Process steps:

1.

E-mail address in Vendor Master is mandatory2. Create supply area for Main stores. TC: PK05

3. If required, extend the material to main storage location. TC: MMSC


5. Create scheduling agreement. Put kanban indicator (X) in the additional data

of item.




Schedule line will be generated for the supply of material to main stores.


10. When the material is received at Gate, perform goods receipt into blockedstock (movement type 103). TC: MIGO

11. Once the material reaches Main stores scan the barcode to FULL. TC: PKBC

(At the background GR with 105 movement will happen).


3. External procurement from Vendor directly to shop





Backflush indicator is set for kanban material in the Routing of the assembly, then this material

will be backflushed in all the production orders for that assembly in the relevant plant (Material




(CO11N) or collectively (CO15). Confirmation posts goods issue of components (relevant toconfirmed operation/s) to production order



• Maintain KN01 storage location in the field - production storage location of MRP2 view in

the material master. Back flushing will take place from this location. Field - Storage location

for external procurement should be KN01 in the material master.

• Storage location exclusion is automatic for storage location KN01. If receiving storage

location is other than KN01, Indicator for storage location in MRP4 should be filled with 1.

• Material received from vendor is directly posted to unrestricted stock. Inspection at vendorsplace or vendor’s process control to ensure rejection free material. Inspection set up in Material

master should be inactive.

Process steps:

1. E-mail address in Vendor Master is mandatory

2. Create supply area for kanban stores (KN01). TC: PK05

3. Extend the material to Kanban storage location. TC: MMSC


5. Create scheduling agreement. Put kanban indicator (X) in the additional data

of item.




Schedule line will be generated for the supply of material to kanban store.


10. When the material is received at Gate, perform goods receipt into blocked

stock (movement type 103). TC: MIGO

11. Once the material reaches shop, scan the barcode to FULL. TC: PKBC (At the

background GR with 105 movement will happen).


4. In house production (Between one sub-assembly line to Main assembly)





Backflush indicator is set for kanban material in the Routing of the assembly, then this materialwill be backflushed in all the production orders for that assembly in the relevant plant (Material




(CO11N) or collectively (CO15). Confirmation posts goods issue of components (relevant to

confirmed operation/s) to production order

• Maintain KN01 storage location in the field - production storage location of MRP2 view in

the material master.

• Maintain ‘Kanban Production schedule profile’ in Work scheduling view of the material

master.• Material should have a valid BOM & Routing.

• All components for the assembly should be planned on Consumption based planning (VB) or

they should also be kanban item.(MRP type of child item should NOT be PD).



Process steps:

1. Create supply area for Kanban store (KN01). TC: PK05

2. Extend the material to Kanban storage location. TC: MMSC


4. Create Kanban control cycle. TC:PKMC 5. Print the barcode. TC:PK17


production order will be generated (with release status).


8. Confirm the operations. TC:CO11n / CO15

9. After the confirmation of last operation, scan the barcode to FULL. TC:

PKBC (At the background GR with 101 movement will happen).


IMPORTANT POINTS TO NOTE

Schedule Agreement line items shall be checked for Tax codes, Excise Conditions

as a one time activity. Required corrections should be carried out when you get

error message that excise posting could not be carried out automatically. You

should also get the excise entries posted by competent personnel.

Confirmation of Production Orders is mandatory. You can do this thru’ Tcode

CO11N or CO15. This process triggers posting consumption of kanban

components thru’ Backflush.

In case you did not have sufficient stock of any Backflush item in stock for

consumption at the time of confirmation, but need to continue and make goods

receipt for Production order, you must later on process goods issue of Backflush

items so missed out, in Tcode COGI (select storage location KN01 and execute to

get list of items for which issue is pending) and post goods issues and save. This will

issue the pending components. Execute the report once again to ensure nothing is

left over before TECOing the orders.

Kanban Database Report is available in Tcode ZPKL. You can generate specific

list based on various selection parameters available.



SAP MAIL THRU’ KANBAN WORKFLOW

Please note that the following roles and its related Kanban mail notifications:

INDMM_MM_JOB_PURCHASER_INAV (select your plant)

If you have this role, copy of mail to the vendor will be received in your SAP mail box.

Also, you will receive a mail alert when Schedule Agreement validity has expired

either for date or quantity.

INDPPPP_JOB_PRODCTN_SUPE_INAV (select your plant)

When a kanban production order is generated automatically, an SAP mail will be

received by you.

INDMMMM_JOB_INVENTORY_CL_INAV (select your plant)

If you have this role, you will receive mail notification in SAP mail box for

transferring material against a kanban reservation.

INDPPPP_JOB_MRP_CONTROLE_INAV (select your plant)

If you have this role, a mail alert will be sent to you, when Schedule Agreement

validity has expired either for date or quantity.

List of Role Authorization required for carrying out Kanban Transactions

in SAP.

INDPPPP_JOB_MRP_CONTROLE_INAV (Select your plant in place of INAV)

INDPPPP_JOB_MST_PRD_SCHL_INAV (Select your plant in place of INAV)

INDPPPP_PRODUCTN_OPERATO_INAV (Select your plant in place of INAV)

INDPPPP_JOB_PRODCTN_SUPE_INAV (Select your plant in place of INAV)

INDMMMM_JOB_INVENTORY_CL_INAV (Select your plant in place of INAV)

If you have authorization for one of these roles, you will be able to transact on Kanban

in SAP.

Please ensure that at least one relevant authorization from the above roles is availablebefore you start Kanban transactions in SAP.



KANBAN BUSINESS PROCESS PROCEDURE

Business Process Business Process Procedure

Create Supply Area

(Tcode: PK05)Sre_BPP_05_PP01_PK05_Maintain Supply

Create Control Cycle

(Tcode: PKMC)Sre_BPP_05_PP01_PKMC_Crt_Cntrl Cycle

Sre_BPP_05_PP02_PKMC_Crt Cntrl Cycle_


Sre_BPP_05_PP0!_PKMC_Crt Cntrl CycleC


Sre_BPP_05_PP0%_PKMC_Crt Cntrl Cycle_

Sre_BPP_05_PP0'_PKMC_Crt Cntrl Cycle_

Kanban Transaction through Scanning or

Manual operation.

(Tcode: PKBC) Sre_BPP_05_PP01_PKBC_ScanE)pty*ull.

Event Driven Kanban – Requirement

generation.

(Tcode: PK23) Sre_BPP_05_PP01_P

K2_+enerateKan,a Goods Receipt – India Specific Process

(Tcode: PKBC)/_Sre_BPP_05_PP01_PKBC_ScanE)pty*

Kanban Board – Demand Source view

(Tcode: PK13N)Sre_BPP_05_PP01_PK1/_-e)andSource

Kanban Board – Supply Source view

(Tcode: PK12N)Sre_BPP_05_PP01_P

K12/_SupplySourceK Kanban Evaluation

(Tcode: PK18)Sre_BPP__PP01_PK1_CC_Kan,an_E$a

Kanban Correction

(Tcode: PK50)Sre_BPP__PP01_PK50_Kan,anErrorPro

Kanban Locking & Deleting

(Tcode: PKMC)PP_PKMC_Kan,an&o

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kanban procedure india

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