Understanding Kanban Master Records
Before you can initiate any kanban transactions, you must set up a kanban master record for the item. You set up kanban master records in the Kanban Master Revisions program (P3016). When you set up the kanban master record, you define the information that the system uses to generate the transaction when you initiate a kanban trigger.
Each record in the F3016 table has a unique kanban ID. Each of these kanban records can have multiple containers or cards. The records also appear in the F30161. When you define an item as kanban-controlled, you essentially define the relationship between a supplying location and consuming location. You define a kanban-controlled item by item number, consuming branch/plant, consuming location, supplying branch/plant, and supplying location. The system generates a unique kanban identifier for this specific relationship.
When you have multiple kanban records (kanban IDs) with the same item number, consuming branch/plant, consuming location, supplying branch/plant, and supplying location, the kanban size for each of these records should be the same.
When you set up the item as a kanban item, you define the source type in the kanban master record to indicate how the item is supplied. For example, if the source, or supply, is a manufacturing activity (the item is a subassembly part), the system can generate a work order when the last kanban card is checked out. You select the source type from the 31/RS Replenishment Source UDC table:
DFM Raw In-Process (RIP) - Source Type 0
Supports material movement in the RIP area. Valid locations are not required.
Work center - Source Type 1
Inventory - Source Type 2
Supplier - Source Type 3
Outside assembly - Source Type 4
Transfer Order - Source Type 5
DFM Dual Card - Source Type 6
You also define whether the system transfers a kanban item in a one-phase or two-phase process. When the transfer occurs in one phase, the completed work order or received purchase order quantity is directly transferred to the consuming location. When the kanban is set up as a two-phase kanban, the materials that are being facilitated through the processing of the kanban cards require an additional Complete transaction to make the materials ready for transfer to the consuming location, from the supplying location. For example, this option, enables you to test the materials before they move on to be consumed during subsequent manufacturing operations.
When you set up a kanban master record, you can enter the kanban size manually or define a calculation method. If you manually enter the kanban size on the Kanban Master Revisions form, ensure that the quantity that you enter is large enough to supply the material consumed, according to the replenishment lead time that is defined for the item. If you decide that the system should not override the user-specified kanban size, then you must set the override option in the kanban master record to 1.
If you decide to use a calculation method, you must first define the calculation method in the Kanban Size Calculation Definition program (P3017). You enter the calculation method identifier in the Calculation Method field of the kanban master record.
You then define parameter values in the Kanban Size Calculation Parameter Definition program (P3018) and run the Kanban Size Calculation program (R30450). The system updates the kanban master record with the kanban size, and either the number of cards or quantity per card that the batch program calculated. If more than one kanban master record has the same supplying branch, supplying location, consuming branch, consuming location, and item number, the system uses the calculation value of the first record to calculate the kanban size of the subsequent record.
It is recommended that the first kanban master record have the highest calculation values set up in the Kanban Size Calculation Parameter Definition program (P3018) so that the requirements of the consuming location are met correctly.
When you leave the Calculation Method Identifier field blank, the system supplies the default value of Manual Entry.
When the kanban is a source type 1 (work center), and the item being produced when the kanban is checked out is a rate-scheduled item, you can indicate that you want the rate schedule to be assigned to a particular repetitive line. The line that you specify must be a valid work center in the F30006 table and have a valid line and item relationship.
Given the relationship that you specify between the kanban size and the container size, the system calculates the number of containers. You define each kanban ID with the number of containers, and you can specify as many containers as needed.
For kanbans that are associated with JD Edwards EnterpriseOne Demand Flow® Manufacturing, the kanban sizes that are calculated in JD Edwards EnterpriseOne Demand Flow® Manufacturing populate the kanban size field in base manufacturing. The override flag in the F3016 table is set to 1 for kanban records that are imported from JD Edwards EnterpriseOne Demand Flow® Manufacturing. This prevents the Kanban Size Calculation program (R30450) in Oracle's JD Edwards EnterpriseOne from recalculating the kanban size and overriding the kanban sizes that were calculated in JD Edwards EnterpriseOne Demand Flow® Manufacturing.
DFM kanbans in RIP (source type 0) function within a raw in-process area and require no check-in or check-out. Type 0 kanbans are optional since they perform no transactions. Inventory (source type 2) and Supplier (source type 3) kanbans are checked in to the first-in-RIP location. Once transactions are successfully completed, inventory balances are reflected in the first-in-RIP location. RIP kanbans pull inventory physically from the first-in-RIP location and item completions is performed which reduces the inventory balances in the first-in-RIP location.
Dual card kanbans (source type 6), specify the number of cards that require check-in before replenishment is performed. The transactions are supported by item completions.
Only internal users can maintain kanban records. When you change the kanban quantity, number of cards, or lead time, you can set up the system to initiate workflow to advise the supplier. All users can review kanban records. Each supplier can review only the procurement kanban master records for that supplier.