Introduction
Event kanbans are only created out of the related demand, so event kanbans belong to the make-to-order category. They are triggered and create related issues when you create sales lines, estimate production orders, create kanbans that are supplied through event kanban rules, or run the pegging event processing where inventory has hit a minimum quantity.
Kanban rule setup
A Kanban rule is a material planning and replenishment policy that governs process and transfer activities that are based on kanbans. The kanban rule defines the way in which an item is produced or transferred and links the item to the activities within the production flow.
Event kanban rules define which event triggers the kanban and under what conditions the event kanban should be created.
Pegging tree
The Pegging tree page can be used from the sales order to provide a quick inquiry of the availability of kanbans. To view the pegging tree from the sales order line, select Product and supply > Requirements > View pegging tree button.
The pegging tree shows the kanban issues from the sales order and will show multiple levels down. The kanban jobs provide a quick visual that shows the job status of the kanban. When the job status of the kanban is Completed, a check mark appears in the kanban ticket icon on the pegging tree.
The entire pegging tree can be planned by using the Plan entire pegging tree button. This feature is useful when automatic planning is not set on the event kanban rules.
Item coverage settings
The item coverage settings on the released products define the minimum stock that is required for each coverage dimension. The minimum stock is defined in the Minimum field on the coverage dimensions or by a Min./max. key.
The planned order type can also be configured on the item coverage settings. Where a kanban is used to supply the coverage dimension, this Planned order type is set to Kanban.
Kanban line event
Kanban line events are used to pull required material or semi-finished products to a downstream manufacturing process. Kanban line events are used to supply components that are not stored in a supermarket by the line side because they are not used frequently, or they are used because the ability to supply the upstream work cell or warehouse makes a buffer in the supermarket obsolete.
These Kanbans (manufacturing or withdrawal) are created automatically or manually based on the requirements of the upper level kanban. This type of kanban is suggested where the components that are required vary by event and a high number of variants are required.
Kanban line events can be used where materials are made to order on a feeder cell in a multiple assembly cell structure.
Sales line events
The sales event is triggered by the creation or a change of a sales line, regardless of where the sales line was created. The sales events can also work in conjunction with the Capable to Promise (CTP) delivery date control of the sales line.
Each sales line creates one or multiple kanbans to fulfill the related demand, based on the maximum product quantity that is defined in the kanban rule that corresponds with the maximum handling unit size. The kanban cards that are printed for sales event kanbans contain customer and customer order references and can be used as shipment labels for the handling units.
Scenario:
The speaker cover paint shop production flow supplies painted covers to a supermarket where they can be picked for other manufacturing processes or for sales.
Pierre and Eduardo have analyzed this production flow and decided that certain colors should be handled by using differing kanban strategies. For the runner colors (red, green, and blue) a fixed quantity kanban replenishment strategy was chosen. An event kanban rule was also set up for the runners where a minimum event quantity of 40 is used to pick up the exceptional orders and, instead of depleting the buffer, turn the orders into make-to-order kanbans.
Several colors are built to customer forecasts (yellow, black, and magenta), so Pierre and Eduardo decided to model these items by using scheduled kanbans so that Master planning could be used to plan these future requirements.
Proposed solution for this scenario:
For the uncommon colors (gold, silver, and the new platinum), an event kanban was set up based on the sales line event to the effect that when a sales order for these colors is placed, it directly triggers the event kanban to be manufactured.
The platinum color is configured on the kanban rule with automatic planning. Pierre has set up the production flow activities, item coverage, and kanban rules for this scenario.
BOM line event
Similar to kanban line events, a production order can consume material that is supplied by lean manufacturing. In a mixed mode environment, a production BOM is created based on a production order to withdraw material from warehouses or other upstream processes.
If the warehouse or the upstream process is controlled by event kanbans for any component that is used in the production order, the related kanbans are created on estimation (manufacturing or withdrawal) of the related production order. On estimation of the production orders for the final assembly, the BOM line event kanbans are created and appear on the work cell or the Kanban board for transfer jobs, depending on the activity type. The BOM line for the component that is supplied by a BOM line kanban must be set to a Line type of Pegged supply.
Scenario
This scenario describes a mixed mode manufacturing environment where some parts of a production order are supplied by a kanban. In this scenario, the final assembly resource group is planned with production orders. Standard components that are required for the production order are picked from a supermarket.
Some parts have less demand and are therefore not placed in the supermarket. These "unpopular" items are instead produced to order in the Packaging work cell as event kanbans that are based on a BOM line event.
On estimation, the production orders create the event kanbans that are based on a BOM line event to be produced on the Packaging work cell. Lars, the shop floor execution/production supervisor for Packaging, notices the kanban demand and plans the event kanbans together with the fixed quantity kanbans for the standard components.
Stock replenishment event
When you run Master planning in Supply Chain Management, additional planned orders are created when minimum on-hand is reached. For a lean manufacturing application that surveys minimum on-hand of important parts, the creation of additional planned orders might lead to a delay of a day until the signal for replenishment reaches the replenishing work cell.
Stock replenishment events are useful in a quick turning environment, where safety stock violations must instantly create a kanban (manufacturing or withdrawal) to replenish the missing item. The pegging event processing in lean manufacturing checks minimum inventory for selected kanban rules and creates the needed kanbans to replenish.
Stock replenishment events are used to trigger kanbans based on obtaining a certain level of on-hand inventory. This feature has been integrated within Supply Chain Management, where the item coverage settings on the item define the minimum stock that is required for each coverage dimension.
Scenario
This scenario involves manufacturing a product where the safety stock has been violated due to shipping incoming sales orders. The event kanbans that are based on the stock replenishment event are created to replenish the stock immediately.
In this scenario, the painted speaker covers warehouse is replenished by scheduled kanbans. The speaker cover paint shop cell that replenishes the warehouse can replenish any item in the warehouse within four hours.
Pierre wants to lower the safety stock on the warehouse to less than one day (to a lower lead time than the cycle time of the MRP run). To avoid shortfall, Pierre sets up an event kanban rule based on a stock replenishment event. When the on-hand falls under minimum inventory, a manufacturing kanban is created to replenish the missing items.
Pierre has set up the production flow activities and kanban rules for this scenario. Eduardo defines the safety stock levels for the items and the forecast schedules. Master planning then creates the scheduled kanbans where required. Susan then enters many small orders that reduce inventory of the product and violates the safety stock levels. Susan's entries create event kanbans that Lars notices on the final assembly work cell and expresses the orders for Susan.
Manual creation of event kanbans
Where the event kanban is set up to manually create a kanban based on the sales line event or kanban line event, manual creation can be done either on the Sales order line or the Kanban Details page by going to Production control > Kanban > Kanban job scheduling or to Production control > Kanban > Kanban board for process jobs.
After the sales line has been completed and the event kanbans are generated, select Product and supply > New > Event kanban to generate the sales line events.
Batch processing of event kanbans
Use the Pegging event processing batch process in Supply Chain Management to set up a batch process to create kanbans that are based on events. To run the Pegging event processing, go to Production control > Periodic tasks > Kanban job batch processing > Pegging event processing.
Pegging event processing can be filtered by the production flow, activity, or kanban rule for which to create the event kanbans. It can also be filtered to create event kanbans only for a certain upper level source requirement, for example, a sales order or kanban. The stock replenishment event requires the pegging event processing to create the event kanbans.