SAP Kanban

Production and material flow control in production with SAP Kanban

Your Requirements

  • Short-term replenishment control through consumption
  • Demand-oriented material requirements
  • Simple organization form with simplification of the planning process

Our Solution

  • Extension of the SAP Kanban processes according to customer requirements
  • Different Kanban methods
  • Diverse application areas: Kanban in production, in external procurement, in meeting requirements from the warehouse

Your Benefits

  • Ensuring production supply
  • Decentralized inventory and procurement responsibility
  • Reduce the administrative effort in production
  • Reduction of stocks lowers costs
  • Implementation completely in SAP

The SERKEM solution in detail

With Kanban, the value chain at each manufacturing or production stage in a multi-stage integration chain can be controlled cost-effectively. For this purpose, reverse-linked containers with control cards are used.

At KANBAN, the material is not pushed into production by the higher-level planning (push), but instead it is called up by the manufacturing level used (pull) if necessary.

The material flow is controlled by containers or by KANBAN cards (Kanban Japanese for card).

KANBAN cards serve as means of identification on the goods and have the advantage that only the physical card or the card information in electronic form (eKANBAN) has to be transported as a signal for replenishment in order to initiate the subsequent delivery.

In the event of production fluctuations, the supply of materials is controlled by the volume of transshipment. A faster consumption increases the circulating speed of the containers. The quantity per container is specified.

Due to the direct alignment of production to customer requirements and the simple mechanism for triggering requirements, inventories can be kept low on the customer and supplier side. The planning and control effort for the order processing process is minimized.

SAP Kanban

If SAP is used to support the Kanban process, system and media breaks can be reduced and the replenishment lead time of materials can be reduced by up to 50%. This is achieved by automating and merging the necessary bookings. Scanning the Kanban cards using mobile scanners can significantly reduce manual entries and thus the error rate.

SAP offers different, location-independent, controllable Kanban methods that can be used in different company areas. SERKEM has further optimized and simplified the SAP Kanban processes. This further increases the efficiency and overview in the Kanban chain.

At a glance

Kanban methodes

  • Classic Kanban
  • Kanban with quantity impulse
  • One-card Kanban
  • Event controlled Kanban
  • Kanban with/without demand planning
  • Without: Components of Kanban parts can only be scheduled based on consumption or procured with Kanban
  • With: Components of Kanban parts can be scheduled as required

  • In-house production
  • External procurement: purchase order, schedule line or quantity release as replenishment element
  • Stock transfer including warehouse management
  • Cross-plant Kanban

The Kanban processes in production are largely automated, production orders and container assignments are carried out automatically.

A Kanban monitor provides transparent information about the status and position of each Kanban container within the circuit at all times.

Unlike in the case of in-house procurement, the scan of the empty container triggers a scheduling agreement for external procurement.

The delivery schedule classification with additional data for item and dates is generated and transmitted to the stored supplier via calls at certain times. All processes now run automatically in the SAP system without any additional manual steps on the part of the employees.

Necessary transport orders for replenishment out of the warehouse are created automatically.

Manual intervention possibilities allow the booking of quantity differences and the flexible allocation of the containers. Replenishment for production can be ensured smoothly.

Suppliers can query the replenishment requirements via the Internet or are directly integrated via EDI. The physical exchange of cards is no longer necessary. Delivery quantities are released according to the delivery schedule.

The Kanban process is seamlessly integrated into incoming goods and quality management, so that JIT and JIS deliveries are made on time.

  • Simple form of short-term replenishment control
  • Pull principle: consumption controls replenishment
  • Direct delivery to consumer
  • Process optimization and shortening the process chain

  • Decentralized inventory and procurement responsibility
  • Production call instead of production planning
  • Manual booking effort is reduced
  • No planning of deployment
  • Lean manufacturing
  • Self-control of the manufacturing process

  • Reduction of stocks lowers costs
  • Automatization of bookings
  • Production quantity corresponds to the current demand

  • Greater transparency of the material flow
  • Reduction of lead times
  • High delivery readiness and meeting deadlines
  • Increased process security

SERKEM offers you the expansion of Kanban processes in the SAP standard:

  • Visualization of the Kanban processes
  • Overview of the status of the Kanban containers
  • Order start monitor: start of production orders based on the current stock situation (process is possible without system-supported Kanban)

  • Management of the containers in a container circuit between company and supplier
  • If the company empties a container, the supplier fills a container
  • When filling the Kanban container, it is not necessary to match the empty and filled container.
  • Traffic light display creates an overview and transparency in container management in SAP: status is color-coded

  • Material relevant for the quality inspection can be posted to the quality inspection stock at the goods receipt
  • Integrated quality inspection in the SAP standard Kanban process

  • Pre-made labels
  • Printing of individual Kanban cards with product images directly from SAP
  • Images are not saved in SAP but locally in the network
  • No need for a document management solution

  • Change of the Kanban status indirectly via processes or directly via input (BDE, RFID, manually)
  • Overview of capacity utilization
  • External Kanban for supplier integration: integrating the suppliers into the Kanban processes, additional Kanban status and the integration into the goods receipt and QM processes
  • Extensions of the SAP Kanban processes in the standard according to customer requirements
  • Kanban container scanning processes automatically trigger follow-up actions in the system

Extract from our References

Logo Schleifring

Schleifring und Apparatebau GmbH

  • Electrical engineering and transmission technologies
  • Turnover: 134 Mio. € (2017)
  • Employees: 650 worldwide (2017)

 

Logo ZF

ZF Friedrichshafen AG

  • Automotive industry
  • Turnover: 16,8 Mrd. €
  • Employees 72.600

Further informationen

Downloads

SAP Kanban