Understanding the Kanban Generation Process
After you set up the item in the Kanban Master Revisions program (P3016), define the calculation method in the Kanban Size Calculation Definition program (P3017) and define parameter values in the Kanban Size Calculation Parameter Definition program (P3018), you can use the Kanban Size Calculation program (R30450) to calculate the size of a kanban. If you already manually entered a kanban size, you can prevent the system from updating the information that you entered by entering 1 in the Override field on the Kanban Master Revisions form.
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 DFM imported kanban records. This prevents the Kanban Size Calculation program (R30450) in JD Edwards EnterpriseOne from recalculating the kanban size and overriding the DFM calculated kanban sizes
When you generate kanbans, you define these processing options:
Specify whether the Kanban Size Calculation program runs in proof or final mode.
Print kanban cards.
Print an exception report for customization purposes.
Update the F3016 table if you are running the program in final mode.
Specify a range, expressed as a percentage, within which the system does not adjust the size of the kanban.
Specify the source of the demand (such as forecasts, sales orders, planned orders, firm orders, and rate schedules).
Specify the aggregation of demand.
Specify the start date to use for the demand calculation.
When you run the Kanban Size Calculation batch program, you use data selection criteria to select records from the Kanban Master table. When you have kanban records (kanban IDs) that have the same item number, consuming branch/plant, consuming location, supplying branch/plant, and supplying location, divide the demand by the number of similar kanban records so that the demand is distributed evenly among the records.
Kanban size is calculated using this formula:
(Kanban size) = [(demand) × ((scan delta days)+ (lead time delivery days))] + (safety stock)
After you run the Kanban Size Calculation program, the system updates the F30161 table with the new kanban size, container size, and number of cards, based on the calculation method that you specified.
The system calculates kanban size for the first record for which you defined kanban-specific values. For kanban-specific records, use the first record's calculation values for the kanban size calculation when subsequent records have the same item number, consuming branch/plant, consuming location, supplying branch/plant, and supplying location. Subsequent records that are similar have the same calculation values and kanban sizes. The kanban size is based on the calculation method that is specified in the Kanban Size Definition program.
After you run the Kanban Size Calculation program, a report displays the new calculated kanban size, container size, number of cards, and previous kanban size.
You can run the Kanban Size Calculation program in either proof mode or final mode. When you run the program in proof mode, it displays the calculated size and does not update the Kanban Card Detail table (F30161).
When you run the program in final mode, it displays the calculated size and updates the F30161 table.
The system assumes that the kanban size is fixed when the maximum and minimum quantities are set to be same for a kanban in the Kanban Size Calculation Parameter Definition program (P3018). The Kanban Size Calculation program (R30450) calculates the number of kanbans required based on the specific size of a kanban.
For calculating the required number of fixed-size kanbans, the system uses following formula:
Number of kanbans = (demand) × (lead time delivery days + scan delta days) / (kanban size – safety stock)
The Kanban Size Calculation program (R30450) compares the number of required kanbans with the current number of kanbans. If the current number is less than the necessary number, the system automatically generates more kanbans. If the current number is larger than the necessary number, the system removes the excessive kanbans from the F3016 table.
The system will not perform any calculation if the kanban is defined with an override flag in Kanban master record.
You can run the Kanban Size Calculation program (R30450) either in proof or final modes. For fixed-size kanbans, the report displays the details of the newly added kanban. In the proof mode, the report lists the new kanbans with sequence numbers and displays a warning message indicating that kanbans will be generated. In final mode the report assigns kanban Ids and displays a message that kanbans have been generated. In case of excess kanbans, the system in proof mode prints a warning message indicating the kanbans to be removed. In the final mode, the system removes the kanbans from the database and prints a message indicating the removal of kanbans.
There should be at least two kanbans for an item with a combination of consuming branch/plant, consuming location, supplying branch/plant, and supplying location. If there is only one kanban, then the Kanban Size Calculation program creates a second kanban with the same attributes as the first kanban. While deleting the excess kanbans, the system leaves two kanbans for an item.