Maintaining Kanban Cards and Replenishment Requests

This chapter provides an overview of the Kanban cards and production replenishment requests and discuss how to:

Create Kanban IDs.
Create manual replenishment requests.
Create Kanban replenishment requests using electronic data collection.
Review Kanban IDs.

Understanding Kanban Cards and Production Replenishment Requests

At the heart of Flow Production involves moving material to a WIP location when it is needed. You can replenish the WIP location from a Inventory location or feeder line or directly from the vendor. Flow Production provides multiple ways to move the material. You can use Kanban cards or replenishment requests with Workflow, you can use pull tickets, or you can use pull lists. You can also use electronic data collection to create replenishment requests.

This section discusses:

Kanban card process.
Replenishment requests (electronic Kanbans).
Kanban ID import integration.
Kanban card and replenishment request printing.

Kanban Card Process

A Kanban card is a physical card that is used to indicate that a WIP location needs to be replenished for a specific item. You can create Kanban cards using the Kanban ID Maintenance page or import them using the Kanban ID Import EIP.

You can print Kanban cards using the Kanban Card Print function. Once you print the cards, their status changes to Open which enables you to perform transactions with the cards using the Kanban ID. You can’t make changes to the card details after the cards are printed; you can change the status only.

Once you have printed the Kanban cards, they can be attached to a box or other container of components and moved to the lineside WIP location. This is done to initially supply the line.

If an item is replenished from a Inventory location, then the Kanban card is taken to the location that is specified on the card, attached to a box of components, and returned to the WIP location. You then scan in the Kanban ID, and the system records the Inventory transfer. Multiple cards cycle between the WIP location and the replenishment source. You add or remove cards based on component usage.

If a replenishment source is a feeder line, the Kanban card is taken to the production area that is specified on the card. In vendor scenarios, you send the Kanban cards to the vendor who ships material based on the number of cards that are received. You receive the shipment using the Kanban receiving process.

You can create Kanban cards that are used multiple times or only once.

Replenishment Requests (Electronic Kanbans)

You create requests when you need to replenish Inventory. Use one of these options to create requests.

You can use the Replenishment Request EIP to replenish components from third-party systems by electronic data collection.

Backflush Controlled

When you record a completion, the system records consumption of components at the WIP locations that are defined for each operation sequence that you backflush. The system compares the on-hand inventory level of the component at the WIP location, after the component has been consumed, to the replenishment point that you establish for the storage location in the Production Replenishment Locations component. If no replenishment point value exists for the WIP location, the system uses the default value for the item from the Define Business Unit Item - Manufacturing: WIP Replenishment page. If the on-hand quantity is below that replenishment point, the system creates a replenishment request in multiples of the value in the Issue Multiple field. This option is useful for assemblies that have a short manufacturing lead-time.

Manual

The manual option uses visual indicators. The indicator might be a light, a gravity feeder, or some other signal to show that the level is low for an item at a WIP location. You use the Create Replenishment Request page to enter the item and WIP location and generate the request.

See Also

Issuing Material to Production

Kanban ID Import Integration

You can import Kanban cards and replenishment requests from third-party Kanban planning systems using the Kanban ID Import EIP.

On the Kanban Replenishment Request process page, if you set the Transaction Source field to External or Both, the system checks whether a third-party Kanban planning system has published any messages (that is, Kanban cards or replenishment requests in XML format). If messages are available, the system processes them. After validating the data, the system assigns a Kanban ID to each request. The requests are available in Flow Production for viewing, printing, and performing transactions.

Kanban Card and Replenishment Request Printing

You can print or reprint Kanban cards for a range of Kanban IDs, item IDs, or WIP locations. You can either send the output to a printer or create a file. The printed Kanban card includes the Kanban ID, item ID, WIP location, replenishment source (inventory, feeder line, or vendor), and quantity. You can also print labels for situations where you want to attach a reusable Kanban card directly to a container, especially if you are using electronic data collection.

You can print Kanban replenishment requests in two formats: Pull List or Pull Ticket.

The pull list is a list of Kanban IDs with associated details, similar to a pick list. You can print the pull list using specific sort and selection criteria.

Pull tickets are similar to Kanban cards. You print one pull ticket per Kanban ID. Once you issue the material requested by a pull ticket, the system changes the Kanban ID status to Complete, as it does for a one-time Kanban card.

PeopleSoft Flow Production Report Descriptions

Common Elements Used in This Chapter

WIP RPL Mode (WIP replenishment mode), WIP RPL Type (WIP replenishment type), WIP RPL Source (WIP replenishment source), and WIP RPL Method (WIP replenishment method)	Displays the values from the Inventory defaults on the Production Replenishment Locations page or—if the values aren’t there—from the item attributes on the Define Business Unit Item - Manufacturing: WIP Replenishment page
WIP Location	Enter the WIP location. The system displays the number of storage levels that are defined for each storage area. If you don’t know which storage location you want, select a storage location field and click the Transfer button to access the Storage Location Search link. The system displays a page where you can search for a storage location at any storage level. Only locations that are defined as WIP locations are displayed.
WIP RPL Status (WIP replenishment status)	Displays the WIP replenishment status. As you move a Kanban card or replenishment request through the Flow Production business process, the system updates the statuses accordingly. The status indicates where the Kanban card is in the replenishment process. Values are: Canceled: The Kanban card is taken out of circulation and can’t be reopened. You must change the Kanban card or replenishment request to this status manually. Complete: You can’t perform transactions using a Kanban card or a replenishment request in this status, but you can reset the status to Open. If the Kanban card’s WIP replenishment type is One Time, then the system sets the Kanban card’s status to Complete once you issue material against the card. Once you complete a Kanban transfer transaction against a replenishment request, the system sets the status to Complete. Because all replenishment requests are one-time only, you can’t record any additional transactions against a Complete replenishment request, but you can reset the status to Open. The Complete status usually means that all possible transactions against the Kanban have been performed. Dispatched: This status is used for replenishment requests that are sourced from a vendor. Once you have run the Dispatch Replenishment Request process (FPS1000), the system sets the replenishment request status to Dispatched and notifies the vendor using the selected dispatch method. This status isn’t used for Kanban cards. Hold: Once the Kanban card or replenishment request is printed, you can change its status to Hold. You can create transactions for the Kanban card or replenishment request only if you reset it to Open. In Process: This status is used for Kanban cards and replenishment requests that are sourced from a vendor. The system sets the Kanban card or replenishment request to this status when it is received from the vendor. If the Kanban card or replenishment request is reusable, then the system sets the status to Open once the material is put away in the WIP location. If you are using a one-time Kanban card or replenishment request, the status changes to Complete once the material is put away. New: Kanban cards are created with this status. You can’t perform transactions against this Kanban card until its status is Open. Printing Kanban cards changes the status from New to Open. Replenishment requests don’t use this status. Open: Once the Kanban card is printed, the system changes its status to Open. For reusable Kanban cards that have Feeder or Inventory as the source, you can continue to cycle them between the WIP location and the replenishment source until you manually change the status. This is the initial status of a replenishment request. Consequently, you can perform transactions against it right away. You cannot do that with Kanban cards. The system doesn’t change the status of replenishment requests when you print them.
WIP RPL Mode (WIP replenishment mode)	Select a mode, which the system uses to determine how replenishment requests are generated for an item. Options are: Backflush Controlled: When you backflush completions, components are consumed in the WIP location. When the quantity on hand falls below the replenishment point, the system generates a replenishment request to bring the on-hand quantity back to the replenishment point. The replenishment request is a multiple of the value defined in the Issue Multiple field. For example, if the replenishment point is 60, the on-hand quantity is 30, and the value in the Issue Multiple field is 20, then the system generates a replenishment request for 40 to bring the on-hand WIP location quantity to the replenishment point. Kanban Card: The replenishment process uses Kanban cards as a manual request for material. In this scenario, Kanban cards are created or imported into the system and then printed. A Kanban card is attached to a box of components; as components are used on the production line, you place the Kanban cards in a Kanban holder. The cards are picked up periodically at the WIP location and taken to a Kanban sorting room or to the source location on the card so that the components can be retrieved. Each Kanban card has a Kanban ID. Manual: When the visual indicator shows that the WIP location needs replenishment, you scan in the item ID and WIP location to generate a replenishment request for the specified value in the Issue Multiple field. This request includes the replenishment quantity and source location that is associated with the item and WIP location.
WIP RPL Type (WIP replenishment type)	For Kanban cards, select the type. Options are One Time and Reusable. The system sets this field to One Time for the WIP replenishment modes Backflush Controlled and Manual. Reusable is the default value for Kanban cards. Workflow: The system generates a worklist entry that displays the Production Replenishment page and the Item, Quantity, and From/To WIP location fields. You can override the values to complete the transfer. This type is valid only if the WIP replenishment mode is Backflush Controlled and the replenishment source is Inventory.
WIP RPL Source (WIP replenishment source)	Select to determine which source supplies the WIP location. Options are: Feeder: A feeder line creates subassemblies that are fed into the main production line. Once you have used a certain quantity of the subassemblies, you send a replenishment signal to start production on the feeder line. If you select Feeder as the WIP replenishment source, the system makes the WIP Production Area field available for entry. Enter the area that serves as a feeder line for the item. Feeder lines must use production schedules to track production. Inventory: Replenish the WIP location directly from an inventory location. If you select Inventory as the WIP replenishment source, the system makes the Source Location field available for entry. Enter the storage location that replenishes this item. The Location field isn't mandatory but, if completed, it must be a valid location. Vendor: Use this option to replenish the WIP location by directly receiving purchased components from a vendor. If you select Vendor as the WIP replenishment source, the system makes available the Vendor ID and Vendor Location fields. Enter the Vendor ID and Vendor Location that will directly replenish this item. You can override this prior to dispatch if necessary.
	Click the Storage Location Search button to access the Storage Location Search link. The system displays a page where you can search for a storage location at any storage level. Only the locations that are defined as WIP locations appear.
WIP RPL Method (WIP replenishment method)	Select a method to designate how the replenishment request is communicated. This field is available if the WIP replenishment mode is Backflush Controlled or Manual. The WIP replenishment methods that are available vary by WIP replenishment source. If the WIP replenishment source is Inventory, the Workflow, Pull Ticket, and Pull List WIP replenishment methods are available. If the source is Feeder, then Pull Ticket is the only option. This field is not used if the source is Vendor. Pull Ticket: You create a one-time replenishment request through either a backflush or a manual scan and run the Pull Ticket Print process to print the pull ticket. This is similar to a one-time Kanban card. You scan in the Kanban ID, and the system displays the item, Kanban quantity, source, and WIP location information. Pull List: A pull list is a list of Kanban requests that you use as you do a pick list. You scan in Kanban IDs to transfer quantities. You run the Pull List/Pull Ticket process (FPS6500) on a scheduled basis to pick up new requests. As with pull tickets, you scan in the Kanban ID from the pull list to transact each request.

Creating Kanban Cards

This section discusses how to create Kanban cards.

Pages Used to Create Kanban Cards

Page Name	Object Name	Navigation	Usage
Maintain Kanbans	SF_KANBAN_DTL	Manufacturing Definitions, Kanban, Kanban Cards, Maintain Kanban Cards	Create Kanban cards and maintain Kanban cards and replenishment requests.
Print Kanban Cards	RUN_FPS6510	Manufacturing Definitions, Kanban, Kanban Cards, Print Kanban Cards	Select print options for the Kanban Cards and Kanban Card Labels SQR report (FPS6510).
Kanban Card Range	RUN_FPS6510A	Manufacturing Definitions, Kanban, Kanban Cards, Print Kanban Cards, Kanban Card Range	Select the range of Kanban IDs, item IDs, or WIP locations to be printed on the Kanban Cards and Kanban Card Labels SQR report (FPS6510).

Creating Kanban IDs

Access the Maintain Kanbans page.

Adding a Kanban ID

Kanban ID	Enter a value for the Kanban ID. If you set up automatic numbering for Kanban IDs, the system uses NEXT as the Kanban ID and assigns the next Kanban ID number when you save the Kanban ID.
Transaction Qty (transaction quantity)	Enter the amount of material with which to replenish the location each time you use the Kanban card.
Print Count	Displays the print count, which the system generates each time you print the Kanban card.

See Also

Setting Up Kanban Automatic Numbering

Defining and Maintaining Material Storage Locations

Searching for Material Storage Locations

Defining Manufacturing Information for an Item

Creating Manual Replenishment Requests

This section discusses how to create manual replenishment requests.

Pages Used to Create Manual Replenishment Requests

Page Name	Object Name	Navigation	Usage
Create Replenishment Request	SF_RPL_REQ_EXPRESS	Manufacturing Definitions, Kanban, Electronic Kanbans, Create Electronic Kanbans, Create Replenishment Request	Manually request replenishment.
Pull Ticket/Pull List Options	RUN_FPS6500	Manufacturing Definitions, Kanban, Electronic Kanbans, Create Electronic Kanbans, Print Pull Ticket/Pull List, Pull Ticket/Pull List Options	Indicate how to print pull tickets and pull lists for the Pull Ticket/Pull List SQR report (FPS6500).
Print Pull Ticket/Pull List - Pull Ticket/Pull List Range	RUN_FPS6500A	Manufacturing Definitions, Kanban, Electronic Kanbans, Create Electronic Kanbans, Print Pull Ticket/Pull List, Pull Ticket/Pull List Range	Select the printing range for the Pull Ticket/Pull List SQR report.

Creating Replenishment Requests

Access the Create Replenishment Request page.

Note. The system numbers new replenishment requests when they are saved, so be sure to set up automatic numbering for Kanban IDs before creating replenishment requests.

Transaction Qty (transaction quantity)

Enter the transaction quantity. The quantity appears by default from the Issue Multiple field, which is defined on the Production Replenishment Location page or the Define Business Unit Item - Manufacturing: WIP Replenishment page. You can override the value here.

See Also

Creating Kanban Cards

Defining Manufacturing Information for an Item

Setting Up Kanban Automatic Numbering

Using the Replenishment Method

Creating Replenishment Requests Using Electronic Data Collection

If you use manual replenishment with electronic data collection, you use the Manual Replenishment page to create replenishment requests. In this scenario, a worker physically inspects the WIP location levels. If the level is low for an item, the worker scans the item and WIP location using a data collection device, and the system generates an electronic data collection replenishment request. Alternatively, the worker can manually enter the request using the Manual Replenishment page.

The Replenishment Request EIP enables third-party systems to create a replenishment request and the message be imported into Flow Production. This EIP is an outbound, batch subscribe, asynchronous message.

Flow Production provides the Replenishment Request Dispatch EIP to enable you to inform vendors of the need to replenish a specific item or location. This EIP is an outbound, batch subscribe, asynchronous message.

This section discusses how to:

Use the Scan Electronic Kanban request.
Run the Kanban Replenishment Request COBOL process (FPPAREPL).

Pages Used to Create Replenishment Requests Using Electronic Data Collection

Page Name	Object Name	Navigation	Usage
Scan Electronic Kanbans	BCT_MG_KANBAN_MRR	Manufacturing Definitions, Kanban, Electronic Kanbans, Scan Electronic Kanbans SCM Integrations, Create Transactions, Manufacturing, Scan Electronic Kanbans	Generate a manual replenishment request with electronic data collection.
Process Kanbans	BCT_FP_REQREPL	Manufacturing Definitions, Kanban, Electronic Kanbans, Process Kanbans SCM Integrations, Process Transactions, Manufacturing, Process Electronic Kanbans	Process replenishment requests. If you use an electronic data collection system, you can run the Kanban Replenishment Request process (to update the system with the replenishment request data that you collect.

Page Name

Object Name

Navigation

Usage

Scan Electronic Kanbans

BCT_MG_KANBAN_MRR

Manufacturing Definitions, Kanban, Electronic Kanbans, Scan Electronic Kanbans
SCM Integrations, Create Transactions, Manufacturing, Scan Electronic Kanbans

Generate a manual replenishment request with electronic data collection.

Process Kanbans

BCT_FP_REQREPL

Manufacturing Definitions, Kanban, Electronic Kanbans, Process Kanbans
SCM Integrations, Process Transactions, Manufacturing, Process Electronic Kanbans

Process replenishment requests.

If you use an electronic data collection system, you can run the Kanban Replenishment Request process (to update the system with the replenishment request data that you collect.

Using the Scan Electronic Kanban Request

Access the Scan Electronic Kanbans page.

Item ID

Select an item. The system displays the source code and description of the item.

Get Repl Data (get replenishment data)

Click to populate the WIP replenishment fields with default values.

Note. If you save the page without clicking the Get Repl Data button, the system saves the record with the WIP replenishment defaults without displaying the data.

Transaction Qty(transaction quantity)

Enter a quantity for the replenishment request.

Source Location

If sourcing this request from an inventory location, enter the source location.

Vendor ID and Vendor Location

Enter the vendor and location if you source the request from a vendor.

Production Area

Enter the production area if you source from a feeder line.

Before you can review and perform transactions on this request, run the Kanban Replenishment Request process.

You can view Kanban completions and correct errors using the Transaction Maintenance component under SCM Integrations.

Running the Kanban Replenishment Request COBOL Process (FPPAREPL)

Access the Kanban Replenishment Request page.

Trans Source (transaction source)

Select the source where transactions originate. Options are:

Internal: Requests are generated internally. For example, select this option when using a wedge device or radio frequency unit with electronic data collection.
External: Requests are received from a third-party Kanban planning system. Select this option to import Kanban ID Import EIP transactions.
Both: Requests are generated internally and externally.

While you are running the Kanban Replenishment Request process, you can also run the Pull List/Pull Ticket process. This creates only new pull tickets that are generated by the Kanban Replenishment Request process.

After you click Run, select one of these check boxes:

FPPAREPL	Select to run the Kanban Replenishment Request process, which updates the system with the replenishment request data that is collected electronically.
FPRPLREQ	Select to run a multistep process that includes both the Kanban Replenishment Request process and the Pull List/Pull Ticket process.

See Also

Enterprise PeopleTools 8.46 PeopleBook: Process Scheduler

Reviewing Kanban IDs

Use the Review Electronic Kanbans component for both Kanban cards and replenishment requests. This component enables you to review Kanban IDs by item ID or WIP location. You can view all Kanbans in multiple locations for a specific item or for multiple items in a specific location. You can use this component to mass change the status for all selected Kanbans.

This section discusses how to:

Select Kanban IDs.
Review the Kanban ID summary.
Review the Kanban ID detail.

Pages Used to Review Kanban IDs

Page Name	Object Name	Navigation	Usage
Kanban ID Selection	SF_RVW_RPL_SEL	Manufacturing Definitions, Kanban, Electronic Kanbans, Review Electronic Kanbans, Kanban ID Selection	Choose a range of Kanban IDs to view.
Kanban ID Summary	SF_RVW_RPL_SUM	Manufacturing Definitions, Kanban, Electronic Kanbans, Review Electronic Kanbans, Kanban ID Summary	View summarized replenishment information by Kanban ID.
Kanban ID Detail	SF_RVW_RPL_DTL	Manufacturing Definitions, Kanban, Electronic Kanbans, Review Electronic Kanbans, Kanban ID Detail	View detailed replenishment information by Kanban ID.

Selecting Kanban IDs

Access the Kanban ID Selection page.

Review by Item ID

Select to retrieve Kanbans by item ID. If you select this option, you must enter an item ID.

Review by WIP Location

Select to retrieve Kanbans by WIP location. If you select this option, you must enter a WIP location. If you enter both an item ID and a WIP location, the system selects only the Kanban IDs with that item ID and WIP location.

Search

Click to view the Kanbans that match the criteria specified.

WIP Replenishment Source

Inventory	If you select this check box, then you must enter a source location.
Feeder Line	If you select this check box, then you must enter a production area.
Vendor	If you select this check box, then you must enter a vendor ID.

Reviewing the Kanban ID Summary

Access the Kanban ID Summary page.

Chg Status To (change status to)

Select to perform a mass status change update for all selected Kanban IDs. For example, you can cancel all Kanban cards in a WIP location before adding new cards. Options are Canceled, Hold, New, No Chg (no change), and Open.

Kanban ID

Click to view details of each Kanban card or replenishment request.

Status

Select to change the status on individual Kanbans if necessary.

Reviewing the Kanban ID Detail

Access the Kanban ID Detail page.

Viewing Detail Information

The system displays different details depending on the type of Kanban ID selected:

Inventory	The system displays the WIP replenishment method and the number of storage levels that are defined for each source location.
Feeder	The system displays the production area.
Vendor	The system displays the vendor ID, vendor location, dispatch method, vendor item ID, and vendor quantity.
WIP RPL Status (WIP replenishment status)	Select to change the status for the Kanban ID, if necessary.

Item ID	Select an item. The system displays the source code and description of the item.
Get Repl Data (get replenishment data)	Click to populate the WIP replenishment fields with default values. Note. If you save the page without clicking the Get Repl Data button, the system saves the record with the WIP replenishment defaults without displaying the data.
Transaction Qty(transaction quantity)	Enter a quantity for the replenishment request.
Source Location	If sourcing this request from an inventory location, enter the source location.
Vendor ID and Vendor Location	Enter the vendor and location if you source the request from a vendor.
Production Area	Enter the production area if you source from a feeder line.

Review by Item ID	Select to retrieve Kanbans by item ID. If you select this option, you must enter an item ID.
Review by WIP Location	Select to retrieve Kanbans by WIP location. If you select this option, you must enter a WIP location. If you enter both an item ID and a WIP location, the system selects only the Kanban IDs with that item ID and WIP location.
Search	Click to view the Kanbans that match the criteria specified.

Chg Status To (change status to)	Select to perform a mass status change update for all selected Kanban IDs. For example, you can cancel all Kanban cards in a WIP location before adding new cards. Options are Canceled, Hold, New, No Chg (no change), and Open.
Kanban ID	Click to view details of each Kanban card or replenishment request.
Status	Select to change the status on individual Kanbans if necessary.