Process Diagram Template - SAP Service MarketplaceIntegration with Other SAP Best Practice Processes...

Manufacturing with Kanban Supply into Production RDS

Process Diagram

© 2014 SAP AG or an SAP affiliate company. All rights reserved. 2

Classic Kanban: External Procurement with Scheduling

Agreements

Demand Source: Production Planner

SAP ERP

Icon Name Transaction

Logistics Production

KANBAN Control

KANBAN Board: Demand

Source View

PK13N

Icon Legend

Set Kanban Status to “EMPTY”

A

A

Set Kanban Status to “FULL”

A

Create Replenishment Element: Firmed

Schedule Line

Create Goods Receipt

Provide Goods according to Schedule

Line

Maintain Scheduling Agreement

Create Material Document

Realize that Kanban is consumed

Supplier

Receive filled Kanban Container


Classic Kanban: External Procurement with Just in Time

(JIT) Call


SAP ERP

Icon Name


MRP Evaluations

Stock/Requirements List

MD04


KANBAN Control


Source View

PK13N

Icon Legend

A


B

Create Replenishment Element: JIT

Call


B


B

Provide Goods according to Schedule

Line

Check Dependent Requirements for

Material

A

Make-to-Stock Production –

Discrete Industry (145)

Maintain Scheduling Agreement



Supplier



Integration with Other SAP Best Practice Processes and

Scope Items

The process diagram might contain links to preceding, succeeding, or other related SAP Best Practice Processes or scope items.

Note that these scope items may or may not be part of the solution package.

Refer to the Prerequisite Matrix for the definition which scope items are part of the solution package.


Classic Kanban: External Procurement with Kanban

Calculation

Production Planner

SAP ERP

Icon Name

Logistics Production MRP

Evaluations Stock/Requirements List MD04

Logistics → Production → KANBAN →

Control Cycle → Kanban Calculation →

Create Proposal

PK07

Information Systems → General Report

Selection → Production Planning →

KANBAN → Check Kanban Calculation

Result

PK08N


Control Cycle → Control Cycle

Maintenance

PKMC


Control Cycle → Kanban Calculation →

Unlock Kanbans

PK09

Icon Legend

A

Pre-calculate Kanbans (Kanban Loop Size)

B

Calculate Proposal for Kanban Loop Size

Check and release Proposal

C

B

C

D


Material

A



Verify Changes in Control Cycles

D

Unlock newly created Kanbans (Mass Release)

E

Unlock newly created Kanbans individually

D

E



Scope Items





Classic Kanban: External Procurement with Alerting

Production Planner

SAP ERP

Icon Name


Control Cycle → Control Cycle

Maintenance

PKMC

Logistics Production KANBAN

Control KANBAN Board: Demand

Source View

PK13N


Evaluations → Delayed Replenishment

Elements

PKAL


Kanban Calculation Check Proposal ALRTINBOX

Icon Legend

A

Create Control Cycle with max. empty

Treshold

A

Create Replenishment Element: JIT

Call

B

C

D

Set more than allowed Kanbans to “Empty”

B

Detect Surpassing of max. empty Kanbans

Create Alert

Evaluate Alert List

C

Check Alert Inbox

D

Solve Error Messages



Classic Kanban: In-House Production (Repetitive

Manufacturing)


SAP ERP



MRP Evaluations

Stock/Requirements List

MD04


KANBAN Control


Source View

PK13N

Icon Legend

A


B

Create Replenishment Element: Firmed Planned Order


A




Material

A

Reduce Forecast Planned Orders by

actual Kanban Quantities

Feeder Line: produces according to Kanban

Requirements

Deliver Material to Demanding Source


Supplying Source: Production Planner (Feeder Line)

Page Link


B



Manufacturing)


SAP ERP

Supplying Source: Production Planner (Feeder Line)

Perform REM Backflush

Maintain Firmed Planned Order


Page Link



Scope Items






Manufacturing) with Trigger Point

Production Planner

SAP ERP



KANBAN Control cycle

Change Lifecycle Status

PKLCM


KANBAN Control cycle

Kanban Calculation Unlock

Kanbans

PK09


KANBAN Control


Source View

PK13N

Icon Legend

Release Control Cycle

A A

Unlock Kanbans

B

B

C

Confirm empty Container

C

Empty Container

Set KANBAN to „Waiting“

Check Trigger Point reached

Set all processed Kanbans to EMPTY


Unlock Control Cycle with locked Kanbans

Create Replenishment Elements: Firmed Planned Orders



Manufacturing) with Quantity Signal and Trigger Point

Production Planner

SAP ERP

Icon Name


Control cycle Change Lifecycle

Status

PKLCM


Control cycle Kanban Calculation

Unlock Kanbans

PK09


Control KANBAN Signal Quantity

Signal

PK22

Icon Legend

Release Control Cycle

A A

Unlock Kanbans

B

Set KANBAN Status to In Use

Confirm Withdrawal of Material

C

B

C

Confirm Withdrawal of Material

C

Partially withdraw Material from

Container

Withdraw Material from Container

Page Link




Production Planner

SAP ERP

Icon Name


Control cycle Change Lifecycle

Status

PKLCM


Control cycle Kanban Calculation

Unlock Kanbans

PK09


Control KANBAN Signal Quantity

Signal

PK22

Icon Legend

A

B

C

Check Container Quantity = 0

Confirm Container Consumption

Set KANBAN to „Waiting“

Check Trigger Point reached

Set all processed KANBANS to „EMPTY“

Page Link

Create Replenishment Elements: Firmed Planned Orders




(Feeder Line View)

Production Planner (Feeder Line View)

SAP ERP

Icon Name


Control KANBAN Board: Supply

Source View

PK12N

Icon Legend

A

Confirm Kanban Replenishment

A

Recognize and fulfill Kanban Demand

Set Kanban Status to Full







(Feeder Line View)

Production Planner (Feeder Line View)

SAP ERP

Icon Name


Control KANBAN Board: Supply

Source View

PK12N

Icon Legend

A

Confirm Kanban Replenishment

A

Recognize Kanban Demand

Set Kanban Status to Full




Fulfill Kanban Demand

Set Kanban to In Process

A

Perform Batch Determination

A


Classic Kanban: Stock Transfer (Lean WM)

Production Planner (Demand Source)

SAP ERP



KANBAN Control


Source View

PK13N

Icon Legend


A

A


A

Create Replenishment Element: Reservation


Provide Goods according to Reservation

Maintain Reservation



Warehouse Clerk (Supplying Source)



Classic Kanban: Stock Transfer (Full WM)


SAP ERP



KANBAN Control


Source View

PK13N

Logistics → Production →

KANBAN → Control →

Kanban Board → Supply-

Source View

PK12N

Logistics → Logistics

Execution → Internal Whse

Processes → Stock Transfer

→ Confirm Transfer Order →

Single Document → In One

Step

LT12

Icon Legend

Set Kanban to “Empty”

A

A

Create Replenishment Element: Transport Requirement and Transport Order

Set Kanban to “In Transit”

B

Confirm Transfer Order

C

Set Kanban to “Full”

A

B

C


Recognize and deliver Kanban Demand



Maintain Transfer Requirement and

Transfer Order



Classic Kanban: Stock Transfer (Full WM) with Alerting


SAP ERP



KANBAN Control


Source View

PK13N


Execution → Internal

Whse Processes →

Stock Transfer → Cancel

Transfer Order → Single

Document

LT15



Whse Processes →

Transfer Requirement →

Change

LB02


KANBAN Kanban

Calculation Check

Proposal

ALRTINBOX

Icon Legend

Set Kanban to “Empty”

A A

Create Replenishment Element: Transport Requirement and Transport Order

Delete Transport Order

B

Delete Transfer Requirement

C

B

C


Recognize Kanban Demand but unable to

deliver


Maintain Transfer Order

D

Page Link


Classic Kanban: Stock Transfer (Full WM) with Alerting


SAP ERP



KANBAN Control


Source View

PK13N



Whse Processes →

Stock Transfer → Cancel

Transfer Order → Single

Document

LT15



Whse Processes →

Transfer Requirement →

Change

LB02


KANBAN Kanban

Calculation Check

Proposal

ALRTINBOX

Icon Legend

A

B

C


D

Check Alert Inbox

D

Maintain Transfer Requirement

Create Alert

Change Kanban Status to „Waiting“

Proceed with further Activities

Check Kanban Status

A

Page Link


Event-Driven Kanban: External Processing with Packaging

Instruction and PDF Print of Kanban Card (Variant 1)


SAP ERP


Logistics

Production

KANBAN Control

KANBAN Board:

Demand Source View

PK13N

Icon Legend

Create Event-driven Kanban

A A

Create Replenishment Element: Purchase

Order and print Kanban Card

Set Kanban to “Full “

A


Page Link

Realize that new Kanban is needed

Maintain Purchase Order


Supplier

Provide Goods according to Purchase

Order

Receive Goods





SAP ERP



KANBAN Control

KANBAN Board:

Demand Source View

PK13N

Logistics → Materials

Management →

Inventory Management

→ Goods Movement →

Goods Movement

(MIGO)

MIGO

Icon Legend

A

B

Change Kanban Status to “Empty”

A

Consume Kanban

Delete Kanban

Page Link

Supplier





SAP ERP


Logistics

Production

KANBAN Control

KANBAN Board:

Demand Source

View

PK13N

Logistics →

Materials

Management →

Inventory

Management →

Goods Movement

→ Goods

Movement (MIGO)

MIGO

Icon Legend

Create Event-driven Kanban (Quantity

according to Packaging Instruction)

A

A

Create Replenishment Element: Purchase

Order and print Kanban Card

Post Goods Receipt

B

B

Set Kanban Status to „Full“

Page Link



Incoming Goods Supervisor Supplier

Provide Goods according to Purchase

Order

Receive Goods






SAP ERP

Icon Name

Logistics

Production

KANBAN

Control

KANBAN Board:

Demand Source

View

PK13N

Icon Legend

A


A

Consume Kanban

Delete Kanban

Page Link

Incoming Goods Supervisor Supplier


Event-Driven Kanban: In-House Production with Alerting


SAP ERP



KANBAN Control

KANBAN Board:

Demand Source View

PK13N


KANBAN Control

KANBAN Board:

Supply Source View

PK12N

Icon Legend

Create Event-driven Kanban

A

A

Create Replenishment Element: Planned

Order

Change Kanban Status to “In Transit”

B

Change Kanban Status to “In Process”

B


Recognize Kanban Demand

Production Planner (Feeder Line)

Generate Error Log and display Error Message

Receive filled Kanban

B

Proceed on Kanban as proposed in Error Log and start Production

Change Kanban Status to “In Transit”

B

Page Link

Send Kanban to Demanding Source


Event-Driven Kanban: In-House Production with Alerting


SAP ERP Icon Legend

Production Planner (Feeder Line)




Change Kanban Status to “Full”

A

Page Link


A


Delete Kanban



KANBAN Control

KANBAN Board:

Demand Source View

PK13N A


Repetitive Manufacturing Back Flush

Production Planner

SAP ERP



Repetitive Manufacturing

Backflush REM Backflush

MFBF


Repetitive Manufacturing

Backflush Postprocess

Postprocessing List

MF47

Icon Legend

Create Repetitive Material Backflush

A

A

Create Goods Issue for Consumed Components

Create Goods Receipt for Finished Product

B

Complete Production of Finished Products


Create Post-Processing List

Post Production Costs to relevant Accounts

Check Post-Processing List

B

Solve displayed Issues

Thank you


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Process Diagram Template - SAP Service MarketplaceIntegration with Other SAP Best Practice Processes...

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