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Lean Manufacturing: Kanban and Pull Based Manufacturing

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Lean Manufacturing: Kanban and Pull Based Manufacturing Microsoft Dynamics® AX 2012 Lean Manufacturing: Kanban and Pull Based Manufacturing White Paper This whitepaper introduces a variety of kanban and pull based manufacturing scenarios and how they can be supported with lean manufacturing for Microsoft Dynamics AX 2012. Date: July 2011 http://microsoft.com/dynamics/ax Conrad Volkmann, Senior Program Manager, Manufacturing Send suggestions and comments about this document to [email protected]. Please include the title with your feedback. Table of Contents Introduction ................................................................................................ 4 Purpose of this document ....................................................................................................... 4 Concepts: kanban and replenishment strategies ......................................... 5 Kanban—the definition .......................................................................................................... 5 Circulating cards ................................................................................................................... 5 Single use kanbans and electronic kanban—all types ................................................................. 5 Single usage kanbans ............................................................................................................ 5 Priority kanbans .................................................................................................................... 5 Kanban schedule .................................................................................................................. 5 Replenishment strategy and kanban type ................................................................................. 6 Manufacturing ................................................................................................................... 6 Withdrawal ....................................................................................................................... 6 Replenishment strategies ....................................................................................................... 6 Fixed quantity kanbans ....................................................................................................... 6 Single usage kanbans ......................................................................................................... 7 Production forecast/schedule related kanbans ....................................................................... 7 Event kanbans................................................................................................................... 7 Reconciling master scheduling and lean manufacturing .............................................................. 8 Finite capacity scheduling for lean manufacturing .................................................................. 9 Production flow and activity validations ...................................................................................10 Kanban boards .......................................................................................... 11 The Kanban schedule board ..................................................................................................11 Automatic scheduling of kanban jobs ................................................................................... 11 Manual scheduling ............................................................................................................ 11 The Kanban schedule board ............................................................................................... 12 Lean scheduling groups ..................................................................................................... 12 Unplanned jobs ................................................................................................................ 13 Displaying the kanban schedule .......................................................................................... 13 Size of the kanban symbol in the schedule ........................................................................... 15 Moving jobs in the schedule ............................................................................................... 15 The schedule alert symbol ................................................................................................. 16 Automatic refresh ............................................................................................................. 16 The kanban board for process jobs .........................................................................................17 The job list ....................................................................................................................... 20 Job details ....................................................................................................................... 21 Job and job status registration ........................................................................................... 22 Picking list ....................................................................................................................... 22 Pegging ........................................................................................................................... 23 Information and process FastTab on the right side ................................................................ 23 Registration ..................................................................................................................... 23 Messages ......................................................................................................................... 23 Cycle time performance indicator ........................................................................................ 24 Transfer jobs .................................................................................................................... 25 Kanban quantity overview—finished goods ........................................................................... 25 Kanban quantity overview – material .................................................................................. 26 Job icon legend ................................................................................................................ 26 2 LEAN MANUFACTURING: KANBAN AND PULL BASED MANUFACTURING Automatic refresh ............................................................................................................. 27 The Kanban board for transfer jobs ........................................................................................28 Filtering jobs on the Kanban board for transfer jobs .............................................................. 28 Working with transfer jobs ................................................................................................. 29 Job status registration ....................................................................................................... 30 Update picking list ............................................................................................................ 31 Replenishment strategies ......................................................................... 31 Fixed quantity kanbans – the circulation principle ....................................................................31 Kanban quantity calculation ............................................................................................... 31 Scheduled kanbans ..............................................................................................................32 Event kanbans .....................................................................................................................32 The sales event ................................................................................................................ 33 The kanban line event ....................................................................................................... 33 The BOM line event ........................................................................................................... 34 Pegging event processing .................................................................................................. 35 The minimum stock event .................................................................................................. 35 Lean supply policies - the kanban rules .................................................... 36 Configuration of kanban rules ................................................................................................36 Filter kanban rules: ........................................................................................................... 37 Activities, kanban flow and production flow .......................................................................... 38 The product selection ........................................................................................................ 38 Quantities ........................................................................................................................ 38 Kanban cards ................................................................................................................... 39 Configuration of events ..................................................................................................... 40 Manufacturing scenarios with kanbans ..................................................... 40 Single process activity production scenario ..............................................................................40
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