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Krishnendu Das
January 6, 2014 | 4 minute read
KANBAN Execution- Step by Step
Approach
40 62 86,660
KANBAN is a process by which material can be replenished as per the
requirement. KANBAN is a Japanese technology for material replenishment.
KAN- means card and BAN means signal. Hence understanding is card which will
give the signal for replenishment stock.
KANBAN will have plastic bins and cards. The card will hold the material no,
storage location, Bar code, material qty etc and will be kept on the bin once the
bin is full. Once the bin is empty, then the card will be on the board. Like that
multiple card will be there for a single material with proper serial no.
KANBAN is having two master data.
1. Control cycle
2. Supply area
First of all supply area will be created with storage location and responsible
person.
T code PK05. Put the plant and create new entry.
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Put storage location and responsible person and save the data.
Go to MMSC
Exclude the storage location from planning(as this is not required to plan through
MRP). We can exclude the storage location from customizing also. In this case all
the material in the storage location will be excluded for planning.
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Now the control cycle has to be created.
T code PK01
Put material, plant, supply area and select classic KANBAN.
Put no of KANBAN (means no of bins), No of KANBAN quantity and maximum
empty allowed.
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Select production type also (inhouse/external).
This can be done through control cycle maintenance also. T code PKMC. To create
new click on
Now check MD04 screen
Total stock is 63 and is excluded from MRP. This stock will be consumed in
subsequent stage(in next stage)
Now check the status of the KANBAN bin. T code PK13N
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Here three bins are full and two bins are in Wait status. Click to see the
legends.
Two important status of KANBAN is.
If Bins are made full- GR will be done
If Bins are made empty-Procurement proposal will be created (NOT GI WILL BE
DONE)
GI is being done through backflush.
In actual situation bins are being scanned through RF device and scanning is
being done one the Bins are empty or Full.
But here we will do through this tab.
Let’s select one bin and make it empty by
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One KANBAN processed and Bin became RED. This means Bin is empty.
Now check MD04. One Production order created (as empty means one proposal
will be created).
Make another Bin empty is same process and see MD04 screen.
Release both the order. The order type of KANBAN is PP05.
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Double click on the Bin and you can see the details with order created.
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Check the stock in MMBE
Stock is 63. Now select one empty Bin in make it Full
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The Bin became green.
Check the stock
Its become 70 unrestricted. Hence 7 nos GR is happened.
Repeat the process and check the qty .More 7 no GR happened
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Check MD04. No proposal exist (for all orders GR happened).
Few more useful T codes
PK11: Plant overview.
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PK18: For each material production order, DOC no on which the production order
got posted can be seen. Status of KANBAN container will be displays also.
PK31: Error in KANBAN can be checked. Select any error line and click on Bell. You
can change the error status.
PK09: KANBAN can be locked (when the KANBAN is not is used/Bin is
damaged).
Alert Moderator
Assigned Tags
MAN Production Planning (PP)
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Related Questions
Supply Area to production line
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By Former Member May 07, 2018
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40 Comments
You must be Logged on to comment or reply to a post.
Aditya S
January 6, 2014 at 11:42 am
Hello Krishnendu,
Thanks for the document and i had given reward points for the same.
1)Can you please confirm do we need to make any configuration settings for the automatic creation of
Production Order(Procurement Proposal) when the bin is empty.
2) Can we use KANBAN instead of MRP. Is KANBAN an alternative to MRP. Please clarify. If no, in which
instances we use KANBAN instead of MRP. thanks.
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Krishnendu Das | Blog Post Author
January 6, 2014 at 11:56 am
Hi Aditya,
Thanks .
1. Not required. I have not created. though I will check again.
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2. For KANBAN material, MRP is not required. But there is a definition of KANBAN material.
KANBAN material will be handled through BINS. Hence one big finished product can't be handled
through KANBAN.
Success.
Regards,
Krishnendu
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Aditya S
January 6, 2014 at 1:26 pm
Hi Krishnendu, Thanks for clarifications.
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Former Member
January 6, 2014 at 12:35 pm
Hi Aditya
To my knowledge, Kanban or MRP is your decision of planning strategy. For a product or a
component which is constantly required or consumed with a very stable demand, a planner
doesn't want to spend more energy on it. So a Kanban control cycle can save a lot of time for the
planner because the shopfloor guys will control the supply. In some case, if a material has a low
value but meanwhile it's continuously required, the MRP controller maybe want to use Kanban
also.
milk
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Aditya S
January 6, 2014 at 1:26 pm
Hi Milk,
Thanks a lot for your inputs on KANBAN usage.
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Tin Dinh Trung
January 7, 2014 at 3:21 am
Thanks for your sharing
Regards
Dinh Trung Tin
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Rajender ch
January 7, 2014 at 5:02 am
Hi Krishnendu,
Thanks a lot for your inputs on KANBAN. Can you please publish any document on kanban using MRP.
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Krishnendu Das | Blog Post Author
January 7, 2014 at 6:06 am
Hi Raj,
If KANBAN is there, MRP is not required. Do you have any such scenario where you have to do
both.
Let me know. Then I can have a re look.
Thanks .
Regards,
Krishnendu.
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Rajender ch
January 8, 2014 at 5:37 am
Thanks Krishnendu for your reply,
I think some where in SCM 350 (KANBAN) book, I have read the Kanban process using
MRP,
Can you please have a look and let us make aware by preparing the business cycle as you
produced right now.
Thanks a lot.
Best regards
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Krishnendu Das | Blog Post Author
January 8, 2014 at 5:44 am
Sure Raj,
Will come back to you.
Regards,
Krishnendu.
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Srini Ravindra Kumar Pandi Gurusamy
January 30, 2014 at 10:28 am
Raj, The MRP4 view setting on MRP exclusion/inclusion indicator decides what
strategy is actually proposed in the control cycle. In this demo you can see that the
material is excluded and hence it has proposed non-MRP strategy 0003 (others
are 0001/0002). If the MRP4 setting for this material is changed to be included
for MRP, the control cycle for same material will propose the I/H strategy as
0004/0005/0006 which are ones to work with MRP. Hope it clarifies your doubt.
Cheers!!!
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Former Member
January 8, 2014 at 4:56 am
Hi,
Very useful document. Full KANBAN cycle has been discussed. Keep posting like this.
Sidhartha.
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Krishnendu Das | Blog Post Author
January 8, 2014 at 5:01 am
Thanks Sidhartha.
Regards,
Krishnendu.
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Former Member
January 20, 2014 at 11:59 am
Thanks lot
Regards,
sabhapathy R
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Tejas Kantilal Pujara
January 24, 2014 at 7:39 am
Good document for beginners to understand KANBAN!!!!!!!!
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Krishnendu Das | Blog Post Author
January 24, 2014 at 7:57 am
Thanks Tejas .
Regards,
Krishnendu.
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Srini Ravindra Kumar Pandi Gurusamy
January 30, 2014 at 10:22 am
Good document Krishnendu.
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Dhaval Choksi
February 7, 2014 at 9:24 am
Thanks for sharing.
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SAP Bagur
February 7, 2014 at 10:31 am
Thanks for Sharing .
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Manish Negi
February 12, 2014 at 9:03 am
Nice Document...Now i get idea of KANBAN... Thanks for sharing it
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Krishnendu Das | Blog Post Author
February 13, 2014 at 6:01 am
Thanks Manish.
Krishnendu.
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anurudh rathore
February 13, 2014 at 12:03 pm
hi krishnendu,
Nice document.
plz share SOP document also
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Krishnendu Das | Blog Post Author
February 14, 2014 at 4:59 am
Thanks Anurudh. Please refer the link.Already created by Kumar.
Standard SOP Process flow...
Flexible Planning in SOP process flow...
Regards,
Krishnendu.
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Former Member
February 23, 2014 at 3:02 pm
Hi, Krish,
Could you pls share your SOP docs...
when i check XML file is not showing screen shots.
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Thanks...
Sakthivel
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Former Member
February 13, 2014 at 6:02 pm
Good Document and easy to understand
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Krishnendu Das | Blog Post Author
February 14, 2014 at 4:56 am
Thanks Kamal.
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Julio Cesar villegas
February 20, 2014 at 4:49 pm
Hi Krishnendu.,
Very interesting doc... and the applied is clear.
thanks.,
Julio César Villegas
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Former Member
February 1, 2015 at 4:52 am
nice one
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Eric Chen
May 11, 2015 at 4:23 pm
Nice documentation for me to learn KANBAN, very useful.
Many thanks!!
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Former Member
September 10, 2015 at 2:26 pm
VERY NICE
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Former Member
September 13, 2015 at 5:56 pm
Hello Krishnendu Das
Good Explanation , I have One question in Kanban scheduling agreement control cycle,
When the kanban scheduling agreement validity expired and target quantity are met , system allowed to
add new schedule lines in agreement without any warning and error ,when kanban is processed " to empty"
and Post GR when processed "To FULL" however In kanban contract agreement It gives error while
validity is expired, Please suggest .
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Sagar Mane
November 20, 2015 at 6:12 am
Hi Krishnendu,
Really nice document.
Helped a lot in understanding kanban
Regards,
Sagar
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MAHENDRAN PARAMASIVAN
December 29, 2015 at 7:22 am
GOOD EXPLANATION BUT IS THERE ANY ADVNCED LEVEL KANBAN. WE ARE IN TO THE AUTOMOBILE
WE ARE YET TO IMPLEMENT THE KANBAN. HERE THE STEPS ARE BASIC LEVEL
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Lahiru Fernando
February 26, 2016 at 8:43 am
Dear Experts,
can we do this PKMC to multiple items same time, like we do the mass changing for materials.
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Former Member
May 4, 2016 at 9:58 am
Nice document..,
can any one share the configuration document of Kan ban process?
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Arpit Kumar Patnaik
June 27, 2017 at 12:14 pm
Excellent Document.
Very Helpful
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Former Member
December 13, 2017 at 8:19 am
Hi Krishnendu,
Hope your are doing well
I need your support that Kanban SAP implementation possibility for below ,
1.we have agreement with the supplier to keep stock on his site based on min/max on his warehouse
2.we have 3 sites in different countries and we are keeping aggregating stock at supplier site
3. once the supplier load any partially Qty we should start production to fill his stock with max
we are using SAP so if Kanban SAP process can cover above point or there is other process on SAP
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Franck Zerman
July 30, 2019 at 2:20 pm
I found what I was looking for KANBAN flow.
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Thank you Krishnendu
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AMOL NAMJOSHI
June 15, 2023 at 12:10 pm
Thanks for the Kanban process document and nicely explained.
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AMOL NAMJOSHI
June 15, 2023 at 12:11 pm
Thanks nicely explained.
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