Manufacturing with Kanban Supply into Production (233) SAP Best Practices
Transcription
Manufacturing with Kanban Supply into Production (233) SAP Best Practices
Manufacturing with Kanban Supply into Production (233) SAP Best Practices Purpose, Benefits, and Key Process Steps Purpose This scenario focuses on different approaches to supply the production using Kanban-controlled business processes. Comprehensive presentation of different Kanban processes Benefits The replenishment process controls itself and manual posting is reduced as far as possible. Reduction in lead time and stock. Components are not procured before they are needed (just in time). Prevention of overproduction. Reduction of required storage space. Simple and transparent method of organization. Event control and alerting enable timely reaction to changes and issues in the production process Key Process Steps Creation an maintenance of Kanban control cycles Creating Planned Independent Requirements and Material Requirements Planning (Plant) Classic Kanban: External Procurement with scheduling agreements Classic Kanban with JIT calls, calculation and alerting Classic Kanban: In-house production (repetitive manufacturing) with quantity signal and trigger point Classic Kanban: Stock transfer from warehouse with alerting Event-driven Kanban with packaging instructions and alerting Repetitive manufacturing backflush © 2012 SAP AG. All rights reserved. ‹#› Required SAP Applications and Company Roles Required SAP enhancement package 6 for SAP ERP 6.0 Company Roles Production Planner Shop Floor Specialist Warehouse Clerk Purchaser © 2012 SAP AG. All rights reserved. ‹#› Detailed Process Description Manufacturing with Kanban supply into production The scenario Manufacturing with KANBAN supply into production focuses on a lean production control method within a repetitive manufacturing environment: use of KANBAN processing for lean replenishment Repetitive Manufacturing is commonly used when a production process meets the following criteria: The same or similar products are produced over a lengthy period of time. The products produced are not manufactured in individually defined lots. Instead, total quantity is produced over a certain period at a certain rate per part-period. The products produced always follow the same sequence through the machines and work centers in production. Routings tend to be simple and do not vary much. The KANBAN method for controlling production and material flow is based on the actual stock quantity in production. Material that is required on a regular basis is continually provided in small quantities in production. Replenishment or the production of a material is only triggered when a higher production level actually requires the material. This replenishment is triggered directly in production using previously maintained master data. The entries you have to make in the system are reduced to a minimum. All other actions in the system are carried out automatically in the background. With KANBAN, the production process controls itself and manual posting is reduced as far as possible. The effect of this is a reduction in lead time and in stock. © 2012 SAP AG. All rights reserved. ‹#› Process Flow Diagram Purchaser Manufacturing with Kanban supply into production (233) Procurement of Materials Additional Processes Shopfloor Specialist Production Planner Planned Independent Requirements REM Planning Table Operative MRP Classic Kanban with Scheduling Agreements Replenishment of external procurement material is required? Replenishment of stock transfer material t is required? Classic Kanban with JIT Calls Event-driven Kanben with packaging instructions Postprocessing List Scheduling Agreement with JIT Inbound (230) © 2012 SAP AG. All rights reserved. Classic Kanban: Stock Transfer (Full WM) with Alerting Replenishment of rep. manuf. Material is required? Event-driven Kanban : In-house production Alerting Classic Kanban: In-house production with quantity signal and trigger point Repetitive Manufacturing Backflush End Process Reprocessing List Classic Kanban: In-house Production Classic Kanban: Stock Transfer (Lean WM) GI/GR Slip Agreement in Sales (231) Inventory Consumption @ Standard Cost Inventory Receipt @ Standard Cost Period-End Closing “General” Plant (181) CO-PA =Profitability Analysis, MRP = Material Requirements Planning, GI/GR = Goods Issue/Goods Receipt ‹#› Process Flow Diagram Scheduling Agreement with JIT Inbound (230) Scheduling Agreements? Set Kanban to “EMPTY” Set Kanban to “FULL” JIT Calls? Check Dependent Requirements Set Kanban to “EMPTY” Unlock Kanbans Alerting Create Eventdriven Kanban Set Kanban to “FULL” Eventdriven/ Packaging Instr.? Warehouse Clerk Production Planner Additional Processes External Procurement using Kanban Set Kanban to “FULL” Kanban Precalculation Release Proposal Check changes and calculation Set Kanban to “EMPTY” Goods Receipt Posting GR Slip Inventory Receipt @ Standard Cost Kanban set to “FULL” GR = Goods Receipt © 2012 SAP AG. All rights reserved. ‹#› Process Flow Diagram In-house Production with quantity signal and trigger point? Release Control Cycle Unlock Kanbans Set Kanban to “EMPTY” Set Kanban to “FULL” Kanban withdawal In-house Production (Eventdriven)? Create evendriven Kanban Check Kanban Status Set Kanban to “IN PROCESS” Set Kanban to “IN TRANSIT” Set Kanban to “FULL” In-house Production Set Kanban to “EMPTY” Set Kanban to “FULL” Stock Transfer (Lean WM)? Set Kanban to “EMPTY” Set Kanban to “FULL” Stock Transfer (Full WM)? Set Kanban to “EMPTY Set Kanban to “IN TRANSIT” Warehouse Clerk Production Planner In-House Production and Stock Transfer using Kanban © 2012 SAP AG. All rights reserved. Set Kanban to “FULL” Set Kanban to “EMPTY” Alerting Confirm Transfer ORder ‹#› Legend <Function> Symbol Description Usage Comments Band: Identifies a user role, such as Accounts Payable Clerk or Sales Representative. This band can also identify an organization unit or group, rather than a specific role. Role band contains tasks common to that role. Symbol Diagram Connection The other process flow symbols in this table go into these rows. You have as many rows as required to cover all of the roles in the scenario. External to SAP External Events: Contains events that start or end the scenario, or influence the course of events in the scenario. Business Activity / Event SubProcess Reference Process Decision Flow line (solid): Line indicates the normal sequence of steps and direction of flow in the scenario. Flow line (dashed): Line indicates flow to infrequently-used or conditional tasks in a scenario. Line can also lead to documents involved in the process flow. Connects two tasks in a scenario process or a non-step event Business Activity / Event: Identifies an action that either leads into or out of the scenario, or an outside Process that happens during the scenario Does not correspond to a task step in the document Unit Process: Identifies a task that is covered in a step-by-step manner in the scenario Corresponds to a task step in the document To next / From last Diagram: Leads to the next / previous page of the Diagram Flow chart continues on the next / previous page Hardcopy / Document: Identifies a printed document, report, or form Does not correspond to a task step in a document; instead, it is used to reflect a document generated by a task step; this shape does not have any outgoing flow lines Financial Actuals: Indicates a financial posting document Does not correspond to a task step in a document; instead, it is used to reflect a document generated by a task step; this shape does not have any outgoing flow lines Budget Planning: Indicates a budget planning document Does not correspond to a task step in a document; instead, it is used to reflect a document generated by a task step; this shape does not have any outgoing flow lines Manual Process: Covers a task that is manually done Does not generally correspond to a task step in a document; instead, it is used to reflect a task that is manually performed, such as unloading a truck in the warehouse, which affects the process flow. Existing Version / Data: This block covers data that feeds in from an external process Does not generally correspond to a task step in a document; instead, this shape reflects data coming from an external source; this step does not have any incoming flow lines System Pass / Fail Decision: This block covers an automatic decision made by the software Does not generally correspond to a task step in the document; instead it is used to reflect an automatic decision by the system that is made after a step has been executed. Financial Actuals Process Reference: If the scenario references another scenario in total, put the scenario number and name here. Corresponds to a task step in the document Sub-Process Reference: If the scenario references another scenario in part, put the scenario number, name, and the step numbers from that scenario here Corresponds to a task step in the document Process Decision: Identifies a decision / branching point, signifying a choice to be made by the end user. Lines represent different choices emerging from different parts of the diamond. Does not usually correspond to a task step in the document; Reflects a choice to be made after step execution © 2012 SAP AG. All rights reserved. Usage Comments Hardcopy / Document Budget Planning Unit Process Process Reference Description Manual Process Existing Version / Data System Pass/Fail Decision ‹#› © 2012 SAP AG. All rights reserved No part of this publication may be reproduced or transmitted in any form or for any purpose without the express permission of SAP AG. The information contained herein may be changed without prior notice. Some software products marketed by SAP AG and its distributors contain proprietary software components of other software vendors. Microsoft, Windows, Excel, Outlook, PowerPoint, Silverlight, and Visual Studio are registered trademarks of Microsoft Corporation. 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