Understanding Inventory Replenishment
This chapter provides overviews of inventory replenishment, vendor replenishment, and Kanban completions processing and discusses how to:
Manage inventory replenishment.
Manage vendor replenishment.
Manage feeder line replenishment.
Understanding Inventory Replenishment
If you are replenishing components from a Inventory location, you use bin-to-bin transfers to move the material. With Flow Production, we provide specific functionality to streamline Kanban transfers.
Understanding the Kanban Transfer Process
You can create Kanban transfers either for Kanban cards or replenishment requests.
If you use Kanban transfers, you must complete the transfer and then run the Inventory Transfer COBOL process (INPTTRFR). This is a good method if you are entering multiple transfers. Express Kanban transfers are best for single transfers as the system updates the database with each transfer and you don't need to run the Inventory Transfer process.
Understanding Kanban Card Transfers
In this scenario, the Kanban card travels back and forth between the WIP location and an inventory storage location. The Kanban card includes the inventory location and Kanban quantity. You take the card to the inventory location and enter or scan the Kanban ID so that it appears on the Kanban Transfer page. Once you enter the Kanban ID, the system provides the WIP location, item, source location, and Kanban quantity. You can override the source location and the quantity.
Replenishment Request Transfers
In this scenario, you create the replenishment request either manually or through backflushing. You can print the Kanban details on a Pull List or Pull Ticket. If you use backflushing, a worklist entry is generated. If you use a Pull List or Pull Ticket, you scan the Kanban ID into the Kanban transfer transaction. The system then provides the destination, source locations, and transfer quantity.
If the replenishment method is Workflow, the system creates a worklist entry after the request is generated. When you select the worklist entry, the system displays the Kanban Transfer page, where you can complete the transfer.
Understanding Vendor Replenishment
If you are using vendor replenishment, you can receive material that is associated with a specific Kanban ID. Purchasing must be installed to use the vendor replenishment features of Flow Production.
You can record Kanban receipts either for Kanban cards or replenishment requests.
Receipt of Kanban Cards
You first must create a purchase order with the PO type Kanban and you must create the Kanban cards.
You send the Kanban cards to the vendor, who receives the cards and ships material based on the number of cards received. The Kanban cards include the vendor name, vendor location, item ID, quantity, unit of measure (UOM), and the ship to information so that the vendor knows where to ship the goods.
The cards are then returned on the next shipment from the vendor, and you scan the Kanban IDs so that they appear on the Kanban Receiving page.
You enter the header details, such as the carrier and bill of lading number, and then you can scan multiple Kanban IDs for the receipt. The Kanban ID includes the item ID, vendor, vendor location, quantity, UOM, and WIP location. Each Kanban ID is saved individually. When you receive all Kanban IDs for the carrier and bill of lading, you select the End of Transaction check box and save the page. You can also receive lot- and serial-controlled items.
You run the Receive Load Application Engine process (PO_RECVLOAD), which determines the PO to associate with the receipt using Purchasing defaults that you define at the item level. If multiple open Kanban POs exist, the Receive Load process selects the oldest PO schedule line that is not past due. You can include open past due PO schedule lines by selecting the Include Past Due Kanban POs check box.
The receipt lines are then processed as normal and the inventory is put away. Once you have received a Kanban ID, the system changes the status to In Process. When the material is put away, the system sets the status to Open if it is a reusable Kanban card. Otherwise, the system sets the status to Complete.
Note. When creating a PO for vendor replenishment, you must make sure that you set the PO type on the PO Header page to Kanban.
You can view the Kanban ID on the Receiving and Inventory Putaway pages, and you can view the receipt transaction in the Inventory Transaction History tables.
See Also
Running the Receive Load Process
Receipt of Replenishment Requests
You must first create a PO with the PO type Kanban, and you must create replenishment requests either manually or by using backflushing. The request includes the replenishment dispatch method, vendor item, and vendor quantity.
Once you create the request, you can review it using the Review Electronic Kanbans component before dispatch, and you can override the vendor and vendor location, if necessary.
Use the Dispatch Vendor Replenishment Request process (FPS1000) to distribute a request based on the dispatch method assigned to the request. You can specify either a single replenishment request or multiple requests for the combination of vendor and vendor location.
Once you run the dispatch process, the system sets the replenishment request status to Dispatched and notifies the vendor by the selected dispatch method. The vendor ships the material, and you receive it using the Kanban Receiving process.
You enter the header details, such as the carrier and bill of lading number. Then you can scan multiple Kanban IDs for the receipt. The Kanban ID includes the item, vendor, vendor location, quantity, UOM, and WIP location. Each Kanban ID is saved individually. When you receive all Kanban IDs for the carrier and bill of lading, you select the End of Transaction check box and save the page. You can also receive lot- and serial-controlled items.
You run the Receive Load process to determine the PO to associate with the receipt based on rules defined at the item level. The receipt lines are then processed as normal and the material is put away. Once you receive a Kanban ID, the system changes the status to In Process and when the material is put away, the system sets the status to Complete.
Note. When creating a Purchase Order for vendor replenishment, you must make sure you set the PO type in the PO Header page to Kanban.
You can then view the Kanban ID in the Receiving and Inventory Putaway pages, and you can view the receipt transaction in the Inventory Transaction History tables.
See Also
Entering Purchase Order Line Details
Understanding Kanban Completions ProcessingIf you are replenishing a component from a feeder line, you use the Kanban Completions process to initiate the replenishment. You can record Kanban completions either for Kanban cards or replenishment requests.
Kanban Card Completions
You collect the Kanban card from the WIP location and take it to the production area or feeder line that is specified on the card. This card is used as a request to start production of the subassembly, and it is attached directly to the subassembly on the feeder line. At the end of the feeder line, you scan the Kanban ID so that it appears on the Kanban Completions page.
Once the transaction is completed, if processing a one-time Kanban card, the system sets the Kanban status to Complete. If processing a reusable Kanban card, the status remains Open.
You then need to run the Completions/Scrap Update process (SFPDCDRV) in Manufacturing. Once you run this process, the system logs each Kanban completion transaction, including the Kanban ID, to the Inventory Transaction History table. You can then use the Transaction History Inquiry page to track the Kanban card.
See Also
Running the Completions Update COBOL/SQR Process (SFPDCDRV)
Replenishment Request Completions
For Kanban completions, you generate the replenishment request manually or through backflushing. You then print a Pull Ticket with the relevant item, quantity, and production area details.
Note. You can't set up Kanban IDs with the replenishment mode Pull List or Workflow if a feeder line sources the Kanban IDs.
As with Kanban card completions processing, you print the pull ticket or request to start production, and you attach it to the subassembly on the feeder line. At the end of the feeder line, you scan the Kanban ID so that it appears on the Kanban Completions page.
Once the transaction is completed, the system sets the Kanban status to Complete. You then need to run the Completions/Scrap Update process in Manufacturing. Once you have run this process, the system logs each Kanban completion transaction to the Inventory Transaction History table. You can then use the Transaction History Inquiry page to track the Kanban ID of the replenishment request.
See Also
Running the Completions Update COBOL/SQR Process (SFPDCDRV)
Managing Inventory Replenishment
This section lists prerequisites and discusses how to:
Create Kanban transfer transactions.
Process Kanban transfers.
Create express Kanban transfers.
Prerequisites
Before you create Kanban transfers, you need to:
Set the replenishment source to Inventory for the items that you are transferring.
Create Kanban cards or replenishment requests for the items.
Print Kanban cards or replenishment requests so that they have the status Open.
Pages Used to Manage Inventory Replenishment|
Page Name |
Definition Name |
Navigation |
Usage |
|
BCT_INV_TRFR |
SCM Integrations, Create Transactions, Manufacturing, Scan Kanban Transfers, Scan Kanban Transfers |
Enter or scan in Kanban transfers. Use the Item Transfer transaction code (0601). |
|
|
BCT_INV_REQTRFR |
SCM Integrations, Process Transactions, Inventory, Storage Location Transfer, Storage Location Transfer |
Update the Inventory records with Kanban transfer transactions. |
|
|
SF_PRDN_REPLN |
Production Control, Process Production, Transact Kanbans, Kanban Transfers, Kanban Transfers |
Update the database directly for each Kanban transfer that you enter. |
Creating Kanban Transfer Transactions
Access the Scan Kanban Transfers page (SCM Integrations, Create Transactions, Manufacturing, Scan Kanban Transfers).
The system displays the business unit, last control ID, and transaction code. Use the Item Transfer transaction code (0601) for Kanban transfers. The DeAssociate Item from Container transaction code (0604) and the Debuild Full Container transaction code (0607) are used for inventory transfers for components stored in containers.
Enter a Kanban ID and press Tab.
For the original location, the system displays the storage location information, item ID, Kanban quantity, and standard UOM. If you are transferring lot- or serial-controlled items, select a lot ID or serial ID.
You can override the destination location that the system provides.
Select the Kanban Complete check box when the transaction is completed. The system sets the Kanban status to Complete for replenishment requests and one-time Kanban cards. Reusable Kanban cards retain the status Open. If you deselect the check box; for example, if you are transferring material from multiple locations, then the Kanban status remains Open.
Note. You can reset the Kanban status to Open using the Kanban ID Maintenance page if the Kanban status is accidentally set to Complete.
For the destination location, the system provides the storage location information by default.
See Also
Making Stock Quantity Adjustments and Transfers Within the Business Unit
Processing Kanban Transfers
Access the Storage Location Transfer page (SCM Integrations, Process Transactions, Inventory, Storage Location Transfer, Storage Location Transfer).
Use this process to update the inventory records with Kanban transfer transactions.
Creating Express Kanban Transfers
Access the Kanban Transfers page (Production Control, Process Production, Transact Kanbans, Kanban Transfers, Kanban Transfers).
Destination Location
For the destination location, the system displays the item ID, storage area information, Kanban quantity, and standard UOM. If the item is serial- or lot-controlled, the system displays the serial or lot ID. If the item is stored in containers, the system displays the container ID. The Allow Negative Inventory check box indicates whether negative inventory is allowed for the item.
You can override the original location or the transfer quantity that the system provides. You can view the location quantity available in the Original Location field.
Select the Kanban Complete check box when the transaction is completed. The system sets the Kanban status to Complete. If you deselect the check box; for example, if you are transferring material from multiple locations, then the Kanban status remains Open.
Note. You can reset the Kanban status to Open using the Kanban ID Maintenance page if the Kanban status is accidentally set to Complete.
Managing Vendor Replenishment
This section discusses how to:
Select run control options for dispatch vendor replenishment requests.
Enter selection criteria for dispatch vendor replenishment requests.
Process email dispatches.
Use the Receive by Kanban ID transaction.
Use the Receipt by PO End transaction.
Load receipts.
Prerequisites
Before you receive replenishment requests by vendor, you need to:
Set up the replenishment source to be Vendor for the item you are receiving.
Create Kanban cards or replenishment requests for this item.
Print Kanban cards so that they have the status Open.
Dispatch replenishment requests so they have the status Dispatched.
Create a PO with the PO type Kanban.
Pages Used to Manage Vendor Replenishment|
Page Name |
Definition Name |
Navigation |
Usage |
|
Dispatch Vendor Kanbans - Run Controls |
SF_RUN_RPL_DSPTCH |
Production Control, Process Production, Transact Kanbans, Dispatch Vendor Kanbans, Run Controls |
Specify run control options for the Dispatch Replenishment Requests SQR process (FPS1000). |
|
Dispatch Vendor Kanbans -Selection Criteria |
SF_RUN_RPL_DSPTCH2 |
Production Control, Process Production, Transact Kanbans, Dispatch Vendor Kanbans, Selection Criteria |
Specify selection criteria for the Dispatch Replenishment Requests process. Print the Replenishment Dispatch report. |
|
Process Email Dispatches |
FP_EMAIL_DISPATCH |
Production Control, Process Production, Transact Kanbans, Process Email Dispatches, Process Email Dispatches |
Dispatch replenishment requests that use the email dispatch method and that have failed during a previous run of the Dispatch Replenishment Requests process. |
|
Kanban Receiving |
BCT_PO_RCV_KBN |
Production Control, Process Production, Transact Kanbans, Kanban Receiving, Kanban Receiving |
Use the Receive by Kanban ID transaction (0106) to receive material by Kanban ID. Use the Receipt by PO End transaction (0105) to indicate that you have finished receiving all items for a shipment. |
Selecting Run Control Options for Dispatch
Vendor Replenishment Requests
Access the Run Controls page (Production Control, Process Production, Transact Kanbans, Dispatch Vendor Kanbans, Run Controls).
Note. You need to dispatch replenishment requests that have the WIP replenishment mode Manual or Backflush Controlled.
If you have a single Kanban request for a vendor, select the Kanban ID for that request. If you have multiple Kanban requests for the same vendor, enter the vendor ID, vendor location, and item ID. The system uses the appropriate default Kanban IDs based on the combination of the vendor, location, and item. The vendor location and item ID are optional.
Entering Selection Criteria for Dispatch
Vendor Replenishment Requests
Access Selection Criteria page (Production Control, Process Production, Transact Kanbans, Dispatch Vendor Kanbans, Selection Criteria).
|
Test Dispatch |
Select this option to test the dispatch process before sending a request. |
|
Print Copy |
Select this option to print a dispatch report. |
|
Fax Cover Page |
Select a predefined fax cover page if you are using Fax as the replenishment dispatch method. |
|
Replenishment Dispatch Methods |
Select a replenishment dispatch method. Options are:
If you select Fax or Email, you must set up a fax phone number or email address for the vendor in the Vendor component. If you select EDX, the system generates an application message using the Replenishment Request Dispatch EIP. You then run the Publish Outbound Message process to publish the message to the vendor. |
|
Repl. Req. Statuses to Incl. (replenishment request statuses to include) |
Select an option. If you select Open, the system selects all replenishment requests with an Open status. If you want to redispatch a request for a particular date range, select Dispatched. The system selects all dispatched replenishment requests between the dispatch dates that you specify. Once you run the dispatch process, the system sets the status of all selected requests to Dispatched, and the vendor is notified by the selected dispatch method. If Collaborative Supply Management is installed, once the replenishment is dispatched, vendors can view the request on the internet. Note. When dispatching replenishment requests using email, it is recommended that you run the multistep process FPDSPTCH, which includes the Email Dispatch Application Engine process (FP_EMAIL_ALL). |
See Also
Maintaining Vendor Information
Processing Email Dispatches
Access the Process Email Dispatches page (Production Control, Process Production, Transact Kanbans, Process Email Dispatches, Process Email Dispatches).
Use the Process Email Dispatches page to run the Email Dispatch process. This process dispatches replenishment requests that use the email dispatch method. This process is used if you do not run the multistep process FPDSPTCH when dispatching replenishment requests.
Although you can run this process by itself, it is recommended that you run it with the Dispatch Vendor Replenishment Request process.
Using the Receive by Kanban ID Transaction
Access the Kanban Receiving page (Production Control, Process Production, Transact Kanbans, Kanban Receiving, Kanban Receiving).
Enter the transaction code 0106 for the Receive by Kanban ID transaction. The system displays the transaction number, device ID, date and time, and user ID.
Enter a ship to setID, ship to location, carrier ID, and bill of lading.
You can enter a Inventory business unit and Kanban ID. The system displays the item ID, vendor item ID, vendor ID, vendor location, area, and Kanban quantity associated with the Kanban ID.
Enter the quantity received and UOM. If the item is lot-controlled, a lot ID is required. For a serial-controlled item, the serial ID is required.
If you have additional Kanban IDs to receive for the shipment, deselect the End of Transaction Flag check box. Once you have received all Kanbans IDs for the shipment, you can select the End of Transaction Flag check box. This automatically generates a 0105 transaction to close out the shipment.
Using the Receipt by PO End Transaction
Access the Kanban Receiving page (Production Control, Process Production, Transact Kanbans, Kanban Receiving).
Use the Receipt by PO End transaction (0105) to indicate that you have finished receiving all items for a shipment. If you select the End of Transaction check box while recording a Receive by Kanban ID transaction (0106), you do not need to use this transaction.
Loading Receipts
After using the Kanban Receiving process, you run the Receive Load process to determine the PO to associate with the receipt based on rules defined at the item level. The receipt lines are then processed as normal, and the material is put away. Once you have received the Kanban ID, the system changes the status to In Process. When the material is put away, the system sets the status to Complete.
See Also
Running the Receive Load Process
Managing Feeder Line Replenishment
This section discusses how to process Kanban completions.
Page Used to Manage Feeder Line Replenishment|
Page Name |
Definition Name |
Navigation |
Usage |
|
Kanban Completions |
BCT_MG_KCPL |
|
Replenish WIP locations from feeder lines. Use this page for both Kanban cards and replenishment requests. Use the Kanban Completions transaction code (0217). |
Prerequisites
Before you create Kanban completions, you need to:
Set the replenishment source to Feeder Line for the items that you are completing.
Create Kanban cards or replenishment requests for the items.
Print Kanban cards or replenishment requests so that they have the status Open.
Processing Kanban Completions
Access the Kanban Completions page (Production Control, Process Production, Transact Kanbans, Kanban Completions, Kanban Completions).
The system displays the business unit, last transaction number, and transaction code.
Enter the Kanban ID. The system provides the revision, production area, bill of material (BOM) code, operation sequence, item ID, routing code, back-through operation, completed quantity, and standard UOM. The system assigns the current date to the BOM and routing effective date. This date determines which BOM code and routing code are effective for the completion.
You can view the route-to information for the Kanban ID. The system displays the storage location levels defined for the main assembly line WIP location where the subassemblies are delivered when completed.
Enter a lot ID if the end item is lot-controlled.
If the end item is serial-controlled, enter a completed quantity and click the Refresh button. The system then creates as many Serial ID fields as the completed quantity, and you can enter the serial ID for each completed item. The quantity completed must be a whole number for serial-controlled items.
If there is an existing production schedule for the combination of the item, production area, and date, then the system records the completion against the existing production schedule. Otherwise, the system adds a new production schedule.
Run the Completions/Scrap Update process in Manufacturing to update the production and inventory records.
After you click Run, select one of these options:
Completions/Scrap Update (SFPDCDRV): Select this check box to run the Completions/Scrap Update process.
This process updates the system with the Kanban completions data that is collected electronically.
Completions and Print Rpl Reqs (SFCMPRPL): Select this check box to run a multistep process that includes the Completions/Scrap Update process and the Pull List/Pull Ticket Print process (FPS6500).
Once the transaction is completed, the system sets the Kanban status to Complete if you are processing a one-time Kanban card or a Pull Ticket. If you are processing a reusable Kanban card, the status remains Open.
You can view Kanban completions and correct errors using the Maintain Transactions component under SCM Integrations.
See Also
Running the Completions Update COBOL/SQR Process (SFPDCDRV)