Convert LOS-BTO schedules to next version kanban rules (form)

Next version base data

Select the data type to work with. The options are as follows:

• Parameters – Open the Lean manufacturing next version parameters form to define default parameters that are used in Lean manufacturing. See Lean manufacturing next version parameters (form) for more information.

• Value streams – Open the Lean manufacturing next version value streams form to define the value streams that are converted to operating units in the next version of Lean manufacturing. See Lean manufacturing next version value streams (form) for more information.

• Production flow model – Open the Production flow model form to create and configure production flow models to use in the next version. See Production flow model upgrade (form) for more information.

• Work cells – open the Work cell migration form to define additional settings for current version work cells that will be upgraded to the next version. See Work cells migration (form) for more information.

• Production flows – Open the Production flows form to create next version production flows and production flow activities that identify and describe your company’s basic business processes for lean manufacturing. See Production flows upgrade (form) for more information.

• Standard work days for calendars – Open the Standard work days for calendar form to add the standard work day to your current version calendars. See Standard work days for calendar (form) for more information.

• Lean schedule groups – Open the Lean schedule groups form to define lean schedule groups that you can assign to current version kanbans and LOS-BTO schedules. See Lean schedule groups upgrade (form) for more information.

View current version

For the current version LOS schedules, click LOS lines to open the Lean booked to order schedule form.

Actual version

View the detailed settings that are defined for the current version LOS-BTO schedule.

Kanban and card details

View and enter settings for the next version kanban cards and how they are used.

Event

View and enter for next version event kanban rules.

Product family

View and enter settings to map current version items to next version schedule groups. This tab is available when a kanban template or a LOS-BTO schedule is selected.

Next version activity

Select the activity that is used to filter the current version kanban rules that are displayed in the grid.

Replenishment strategy

Select the replenishment strategy that will be used to generate next version kanban rules. This field filters the kanbans that are displayed in the grid according to type. The options are as follows:

• Fixed – View fixed quantity kanbans that are not pull-to-order (PTO) kanbans or kanban templates. You can convert target and phased target kanbans to fixed quantity kanban rules.

• Scheduled – View current version kanban rules that use the replenishment strategy, target. These rules can be converted to scheduled kanban rules.

• Event – View current version kanban rules that use the replenishment strategy, PTO. These rules can be converted to event kanban rules.

Lean order schedule

View the identification of the current version lean order schedule.

Family group

View the current version family group.

Activity

View the identification of the next version activity.

Register as empty

For the next version kanban rule, select an option to define when material handling units are registered as empty. The options are as follows:

• When handling units are received – When the last job of a kanban is completed, the kanbans are registered as empty and disappear from the kanban quantity overviews. This is the default setting for scheduled kanbans, and it can also be used for the other replenishment strategies. When used with the fixed quantity strategy, a new kanban is created whenever the last job of the previous kanban is completed.

• When the source requirement is registered – When the products that are supplied by event kanbans are consumed by the demand source, the kanbans are registered as empty. They disappear from the kanban quantity overview in the kanban boards.

• Manual (includes scanning empty) – The kanbans must be explicitly registered as empty. Use this setting when products are stored in supermarkets before they are consumed or shipped. This is the default setting for fixed quantity kanbans.

Expires

For the next version kanban rule, select the date when the rule expires.

Auto print kanban

For the next version kanban rule, select the event that causes automatic printing of kanban cards. The options are as follows:

• None – Automatic printing is not used. We recommend that you use this setting when circulating cards or electronic kanban processing is used.

• Creation – Print kanbans when the kanban is created. We recommend that you use this setting when a physical planning board for event kanbans is used, and circulating cards cannot be used.

• Plan – Print kanbans when the first job of the kanban is Planned. We recommend that you use this setting when a printed kanban card triggers the processing of kanban jobs on the shop floor.

• Prepare – Print kanbans when the first job of a kanban flow is registered as Prepared.

• Start – Print kanbans when the first job of a kanban flow is registered as In progress.

• Receive – Print kanbans when the first job of a kanban flow is registered as Completed. This option is often used if batch or serial numbers of the finished items are printed on the kanban card.

Kanban print instructions

For the next version kanban rule, select the information to print on the kanban card. The options are as follows:

• Work instructions – Print the production instructions document that is attached to the kanban.

• Shipping instructions – Print the complete ship to address and tracking information on the kanban card. This includes batch and serial numbers.

Card assignment

For the next version kanban rule, select the method of assigning circulating cards. The options are as follows:

• Automatic – When a kanban is created, a card is assigned automatically when the following conditions are true. An unassigned active kanban and an unassigned active card exist for a kanban rule. This is the default setting.

  When kanbans are created before circulating cards are created, the cards are assigned automatically when the cards are created. If there is a shortage of cards, when a kanban is registered as empty, the card is automatically assigned to a new kanban. This is especially useful when circulating cards correspond to a limited number of conveyers, racks, or bins.

• Manual – You must assign a card manually in the kanban board. You can do this when you prepare a kanban job.

Minimum quantity

For next version scheduled kanban rules, enter the minimum product quantity to use per kanban. The value that is entered in the Default order settings, Inventory quantity, Min. order quantity setting is used as the default value. You can change it, but it cannot be less than the minimum order quantity for inventory.

Allow deviating quantity

Select this check box to allow the finished product quantity to differ from the specified product quantity for each instance of a kanban job that references the kanban rule.

Maximum

Enter the quantity by which the finished product quantity can exceed the specified product quantity.

Alert boundary maximum

Enter a number of kanbans to define the maximum kanban quantity per work cell or supermarket. This boundary helps visualize excess inventory in a supermarket. It also gives a visual signal when more scheduled or event kanbans than expected are created for a kanban rule.

The kanban level is visible in the kanban quantity overview of the kanban boards. When the number of completed jobs for active kanbans is more than the specified maximum alert quantity, the background color is red instead of green. Active kanbans can have any handling unit status except Empty.

Maximum planned jobs

When you use automatic planning of unplanned kanban jobs, enter the maximum number of kanban jobs that are planned for a specific kanban rule. Use this limit to avoid overloading a work cell for scheduled and event kanbans. This situation might occur because of false demand or exceptionally large customer orders.

For sales event kanban rules that use CTP (capable to promise) or automatic kanban creation, we recommend that you use this setting together with a maximum sales order quantity setting. These settings would limit the effect that erroneous order quantities could have on system performance.

BOM line event kanban creation type

Use this setting to configure kanban rules that replenish picking lists that are based on production orders. Select one of the following options:

• Not active – Kanbans are not created for BOM line events.

• Automatic – Kanbans are generated when production orders are estimated, and the BOM lines correspond to kanban rules.

Stock replenishment kanban creation type

Use this setting to configure kanban rules that replenish minimum inventory levels. Select one of the following options:

• Not active – Kanbans are not created for stock replenishment events.

• Batch – Kanbans are generated during pegging event processing if the actual available inventory is below the minimum inventory quantity.

Source requirement registration constraint

Select the status of the source requirement that determines when material handling units of the referenced event kanbans must be received. The options are as follows:

• None – If sufficient inventory is available, the material handling units do not have to be received.

• Picking – Material handling units must be received before the source requirement can be prepared.

• Start – Material handling units must be received before a kanban job or production order can start.

• Finish – Material handling units must be received before a production order can be reported as finished.

• End – Material handling units must be received before a kanban job or production order can be completed.

Source requirement reservation

Select this check box to override the current inventory reservation settings for demand source requirements such as sales order lines and production BOM lines.

Always

Select this field to automatically reserve inventory for all referenced sales lines and production BOM lines.

BOM line reservation method

Select the method of automatic reservation to use for BOM lines. When production BOM lines that reference this kanban rule are created, the setting in this field overrides the default reservation setting.

Percent

Enter the percentage of the item that is allocated to the schedule group.

Throughput ratio

For the selected item or item group, enter a ratio to adjust the standard capacity that is defined for the work cell.

When you use the Throughput method to measure capacity, you can use a throughput ratio to adjust the throughput quantity that is defined. The default value is one, but you can change it. A ratio >1 means that the product consumes more capacity than a standard product. A ratio < 1 means that the product consumes less capacity than a standard product.

When you use the Hours method to measure capacity, the throughput ratio is used to calculate the load as follows. For each job, the average cycle time x throughput ratio is loaded to the work cell schedule.