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80310: LEAN Manufacturing in Microsoft Dynamics AX 2012
Duration: 04 days
Level: 200
This course provides students with a detailed overview of the Lean Manufacturing
module in Microsoft Dynamics AX 2012. It provides a description of the main features
and processes used to run lean manufacturing and includes detailed labs, scenarios,
examples, and demonstrations that range from understanding and configuring
different types of Kanbans, to subcontracting and setting up production flow costing.
80310: LEAN Manufacturing in Microsoft Dynamics AX 2012
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AUDIENCE
This course is intended for:
Partners, consultants, presales consultants, and professionals that have a moderate understanding of basic Lean Manufacturing concepts and production processes.
PREREQUISITES
Before attending this course, students must have:
Basic Knowledge of Lean Manufacturing principles and processes.
Knowledge of Microsoft Dynamics AX 2012 Production.
Knowledge of Microsoft Dynamics AX 2012 Trade and Logistics.
AT COURSE COMPLETION
After completing this course, students will be able to:
Describe the core concepts of Lean manufacturing.
Create a new production flow version and describe activity relations and constraints, picking activities and costing implications.
Define Kanbans and describe their types including: withdrawal, fixed quantity, event, scheduled and subcontracting Kanbans.
Explain how fixed quantity Kanbans are used including how to set up rules, review planning processes, and use the Kanban schedule board.
Describe how event Kanbans are used including how to configure rules, set up sales line events, Kanban line events, BOM line events and stock replenishment events.
Describe the processes associated with the planned order type Kanban.
Define and setup activity based subcontracting.
Describe production flow costing including: back flushing, conversion costs, cost reporting to the general ledger, and how production costing is set up for a Kanban job based on subcontracting activity.
Define how to set up and configure Kanban quantity calculation policies and how to create quantity calculations to generate and update Kanban rules.
COURSE OUTLINE
Module 1: Concepts and Overview
This module provides the conceptual foundation for an appropriate understanding of the basic
concepts in Lean manufacturing, including the structure of the Lean functionality, and the
required setup in Microsoft Dynamics AX 2012.
Lessons
Objectives
80310: LEAN Manufacturing in Microsoft Dynamics AX 2012
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Introduction
Core Concepts
The Value Stream
Introduction to Production Flows
Introduction to Kanbans
Simple Production Flow
High Level Production Flow
Setup and Interconnectivity
Summary
Test Your Knowledge
Quick Interaction: Lessons Learned
Solutions
Lab : No Labs in this module.
After completing this module, students will be able to:
Explain Lean basic concepts.
Explain the Value Stream theory.
Describe the production flow concept and how it is used in Microsoft Dynamics AX 2012.
Explain the Kanban concept and how it is used in Microsoft Dynamics AX 2012.
Describe the Simple Production Flow and the High Level Production flow
Set up time units.
Set up the production flow model and explain the capacity settings.
Set up work cells as resource groups.
Set up Lean schedule groups.
Describe the new inventory breakdown concept for Lean manufacturing in Microsoft Dynamics AX 2012.
Describe standard costing and back flush costing and how they are used in Lean manufacturing in Microsoft Dynamics AX 2012.
Module 2: Production Flows
This module explains the purpose of production flows, how to set them up, how they are vital as
the foundation for the Lean manufacturing in Microsoft Dynamics AX 2012, and the implications
that the production flow has from a costing and inventory point of view.
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Lessons
Objectives
Introduction
Production Flow Versions
Takt and Cycle Times
Activities Setup
Single Transfer Activity Production Flow
Two Activity Production Flow: Process and Transfer
Activity Relations
Multiple Activity Scenarios
Inventory Integration
Semi-Finished
Costing Implications
Summary
Test Your Knowledge
Quick Interaction: Lessons Learned
Solutions
Lab : Creating a Single Process Activity Production Flow
Create a New Resource Group for the Work Cell Steps
Create a New Production Flow and Version Steps 1-8
Create a New Production Flow and Version Steps 9-16
Create a Process Activity Steps 1-7
Create a Process Activity Steps 8-12
Activate the Production Flow Version Steps 1-2
Lab : Multiple Activity Production Flow
Multiple Activity Production Flow Steps 1-8
Multiple Activity Production Flow Steps 9-20
Multiple Activity Production Flow Steps 21-26
After completing this module, students will be able to:
Create a new production flow version.
Set up takt/cycle times.
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Set up process type activities.
Set up single transfer type activities.
Set up a two activity production flow containing transfer and process type activities.
Define predecessors/successors.
Describe activity relations and constraints.
Describe picking activities and setup required.
Describe semi-finished product and setup required.
Describe costing implications.
Module 3: Use and Manage Kanbans
This module provides a base level introduction into the various types of Kanbans and an overview
of how they are best used in the Lean manufacturing production environment.
Lessons
Objectives
Introduction
Kanban Types
Kanban Replenishment Strategies
Subcontracting Activities and Manufacturing Kanbans
Summary
Test Your Knowledge
Quick Interaction: Lessons Learned
Solutions
Lab : No Labs in this module.
After completing this module, students will be able to:
Describe manufacturing Kanbans and explain the different ways they can be used to streamline business processes using Microsoft Dynamics AX 2012.
Define withdrawal Kanbans and explain how they are used to move materials.
Describe fixed quantity Kanbans and how they compare to fixed bin and fixed card Kanban systems.
Define event Kanbans and describe how they can be used to trigger pull events.
Describe scheduled Kanbans and when they should be used.
Describe subcontracting scenarios using Kanbans.
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Module 4: Fixed Quantity Kanbans
This module explains how to set up and process fixed quantity Kanbans, including rule setup, job
planning, using schedule boards, and processing Kanban jobs.
Lessons
Objectives
Introduction
Kanban Rule Setup
Kanban Job Planning
Kanban Printing
Kanban Processing - Process Jobs
Kanban Processing - Transfer Jobs
Summary
Test Your Knowledge
Quick Interaction: Lessons Learned
Solutions
Lab : Configure a Fixed Quantity Kanban Rule
Step by Step: Creating the Kanban Rule for Process Activity
Step by Step: Creating the Kanban Rule for the Transfer Activity
Step by Step: Creating the Standard Cost for the Item
Lab : Planning a Kanban on the Kanban Board
Lab : Kanban Processing on the Kanban Board for Process Jobs
Lab : Kanban Processing on the Kanban Board for Transfer Jobs
After completing this module, students will be able to:
Describe how fixed quantity Kanbans are used in Microsoft Dynamics AX 2012.
Define how to set up and configure fixed quantity Kanban rules.
Review the planning process for a fixed quantity Kanban.
Explain how to use the Kanban schedule board in the planning process for fixed quantity Kanbans.
Explain how to use printing pick lists and Kanban cards to signal processes on the shop floor.
Describe how to use the Kanban board for process jobs when using fixed quantity Kanbans.
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Describe the processing of fixed quantity Kanbans.
Module 5: Event Kanbans
Since event Kanbans are only created out of related demand, they belong to the production
category of “make-to-order" and are created when certain events occur. This module describes
these events and how to set up and process event Kanbans.
Lessons
Objectives
Introduction
Kanban Rule Setup
Sales Line Events
Capable to Promise
Kanban Line Event
BOM Line Event
Stock Replenishment Event
Summary
Test Your Knowledge
Quick Interaction: Lessons Learned
Solutions
Lab : Configure an Event Kanban Rule
Step by Step: Create and Release New Color
Step by Step: Lean Schedule Group
Step by Step: Kanban Rule
Lab : Process a Sales Line Event
Step by Step: Enter Sales Order
Step by Step: Produce Quantity Signaled by Kanban
Step by Step: View Sales Order
Lab : Process a Sales Line Event with CTP
Step by Step: Setup
Step by Step: Kanban Schedule Board
Step by Step: Sales Order
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Lab : Kanban Line Event
Step by Step: Enter Sales Order
Step by Step: Plan the Kanbans
Step by Step: Produce the Kanbans
Step by Step: Transfer the Speaker Set
Lab : Set up a BOM Line Event Kanban Rule
Step by Step: BOM
Step by Step: Production Flow
Step by Step: Kanban Rule
Lab : Process a BOM Line Event
Step by Step: Process a BOM Line Event
Lab : Set up a Stock Replenishment Event Kanban Rule
Step by Step: Item Coverage Settings
Step by Step: Kanban Rule
Lab : Process a Stock Replenishment
Step by Step: Enter Sales Order
Step by Step: Shop the Sales Order
Step by Step: Plan and Prioritize Kanban
After completing this module, students will be able to:
Describe how event Kanbans are used in Microsoft Dynamics AX 2012.
Define how to set up and configure event Kanban rules and the corresponding event types.
Describe how to use the Kanban board for process jobs when you use event Kanbans.
Describe the processing of event Kanban jobs.
Demonstrate how to set up and process a sales line event.
Demonstrate how to set up and process a sales line event with Capable to Promise (CTP).
Demonstrate how to set up and process a Kanban line event.
Demonstrate how to set up and process a BOM line event.
Demonstrate how to set up and process a stock replenishment event.
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Module 6: Scheduled Kanbans
This module explains the setup of a scheduled Kanban rule and describes Master Planning settings
that affect these rules. It also describes how to plan scheduled Kanbans, including how to work
with planned orders, the Supply Overview form, and the scheduled Kanban Process Boards.
Lessons
Objectives
Introduction
Planned Orders of Type Kanban
Supply Schedule
Kanban Rule Setup
Planning Scheduled Kanbans
Summary
Test Your Knowledge
Quick Interaction: Lessons Learned
Solutions
Lab : Scheduled Kanban Rule Setup
Step by Step: Create and Release New Color
Step by Step: Product Family
Step by Step: Lean Schedule Group
Step by Step: Default Order Settings
Step by Step: Kanban Rule
Lab : Scheduled Kanban
Step by Step: Enter Forecast
Step by Step: Run Master Planning
Step by Step: Review Supply Schedule
Step by Step: Plan and Process
After completing this module, students will be able to:
Describe the behavior of planned orders of type Kanban.
Describe the Supply schedule form and the relationship with scheduled Kanbans.
Describe how scheduled Kanbans are used in Microsoft Dynamics AX 2012.
Define how to set up and configure scheduled Kanban rules.
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Describe the planning process for a scheduled Kanban.
Describe the planning considerations for scheduled Kanbans.
Module 7: Activity Based Subcontracting
This module describes how subcontracting can be set up in a Lean production environment to
allow manufacturing activities to be performed by outside vendors.
Lessons
Objectives
Introduction
Subcontracting Vendor Payments
Resource Group/Work Cell
Production Flow with Subcontracting Activities
Subcontracting as an Alternate Resouce
Cost Accounting of Subcontracted Services
Summary
Test Your Knowledge
Quick Interaction: Lessons Learned
Solutions
Lab : Process a Subcontract Activity
Step by Step: Create Kanban Tickets for Withdrawal Kanbans
Step by Step: Create Kanban Tickets for Manufacturing Kanbans
Step by Step: Replenish the Kanban Transfer Job
Step by Step: Plan the Kanban Jobs
Step by Step: Start the Kanban Process Jobs
Step by Step: Release Purchase Orders
Step by Step: Complete the Kanban Process Jobs
Lab : Using an Alternate Subcontractor
Step by Step: Create Kanban Tickets for Manufacturing Kanbans
Step by Step: Assign and Plan Alternate Kanban Rule
After completing this module, students will be able to:
Describe how to set up subcontracting vendor payments.
80310: LEAN Manufacturing in Microsoft Dynamics AX 2012
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Describe how to configure a resource group/work cell as subcontracted.
Describe how activity-based subcontracting is used in Microsoft Dynamics AX 2012.
Define how to set up and configure subcontracting activities in production flows.
Define how to use alternate process flows with subcontracting activities.
Describe how to use the Kanban board for process jobs for subcontracting activities.
Module 8: Production Flow Costing
This module explains the costing setup required to work with production flows in Microsoft
Dynamics AX 2012. It also describes how the flow of costs that originate from the transactions
are used to process the Kanbans within these production flows.
Lessons
Objectives
Introduction
Backflush Costing
Standard Cost Requirement
Components for Lean Manufacturing
Reporting Production Flow Activities
Subcontracting
Backflush Costing
Summary
Test Your Knowledge
Quick Interaction: Lessons Learned
Solutions
Lab : Configure Standard Costing in Microsoft Dynamics AX2012
Step by Step: Costing Version Setup
Step by Step: Cost Group Setup
Step by Step: Set up Shared Categories and Cost Categories
Step by Step: Select Resource Group Cost Categories
Step by Step: Costing Sheet Setup - Part 1
Step by Step: Costing Sheet Setup - Part 2
Step by Step: Product Details
Lab : Calculation of Standard Cost Based on a Production Flow
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Lab : End a Kanban Process Job and Observe Posted Costs
Lab : Costing for Subcontracted Activity
Step by Step: Create Kanbans
Step by Step: Transfer and Produce Kanbans
Step by Step: Review Subcontracting Costing Before and After Receipt of PO
Lab : Perform Periodic Backflush Costing
After completing this module, students will be able to:
Describe the concept of backflush costing and how it is used in Dynamics AX 2012.
Describe conversion cost for items produced by a Kanban in a production flow.
Describe the different calculation methods of standard costs for items produced with a Kanban job.
Understand how costs are reported to the general ledger when producing items using Lean process flows.
Demonstrate how to view the costing for a Kanban job based on a subcontracted activity.
Describe production flow periodic posting using the backflush costing calculation.
Module 9: Kanban Quantity Calculations
This module explains how to setup, use and process Kanban calculations in order to adjust the
Kanban rules.
Lessons
Objectives
Introduction
Kanban Quantity Calculation Policies
Calculating Kanban Quantities
Summary
Test Your Knowledge
Quick Interaction: Lessons Learned
Solutions
Lab : Calculating Kanban Quantities
Step by Step: Review Kanban Quantity Calculation Policy
Step by Step: Kanban Quantity Calculation
After completing this module, students will be able to:
80310: LEAN Manufacturing in Microsoft Dynamics AX 2012
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Define how to set up and configure Kanban quantity calculation policies.
Describe how to create the Kanban quantity calculation to generate, calculate and update Kanban rules.
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