Global SAP Program

Power Conversion
KANBAN by Product Setup & Execution:

Revision #: 3.0

g
Implementation Date:

Expiration Date:

Owner: Olivier Rollot

Author: Derek Martin

Revision
Course Agenda
• This document covers the following:
• Purpose / Introduction
• Process Map
• Production Order Storage Location & Staging setup
1. Master Data Setup & Prioritisation
2. Kanban Master Data setup
3. Kanban process execution
4. Kanban by Product Setup
5. Kanban by Product Example
Purpose / Introduction

Kanban by Product
• Material Staging is the method through which the required
materials and quantities for Manufacturing are transferred or
‘staged’ from the Warehouse Storage Location (from where they
are stored) to the Production Issue Storage Location (from where
they are consumed).
• The 3 main types of staging materials utilised currently in Fusion
SAP
1. Staging via WM Transfer Orders within the same SLoc
2. Staging at IM level
3. Staging via KANBAN replenishment
• All types are driven by the Issue Storage Location assigned on
line items within Production Orders – Master data determines
this.
Purpose / Introduction

Kanban by Product
1. Staging via WM Transfer Orders that are generated via the staging transaction
YMATSTAGE after Production Order release.
 Transferred within the same SLoc from the Warehouse Storage Type &
Bin to Storage Type 700 (Production) and Bin = Prod. Order Number.
Normal WM Staging process

Plant P84A P84A

Storage Location P84A P84A
Storage Type 010 Staging Transfer Order 700
Storage Bin K25305 0001002397
Prod. Consumtion Sloc. N/A P84A
 Purpose / Introduction

Kanban by Product
2. Staging at IM level. Mainly used on materials that are stored and
consumed from the same place (i.e. lineside storage) or materials
transferred in full and not discrete quantities from the Warehouse to
the line (i.e. Full large Drums of cable).
 No Transfer Orders are used. The Non-WM picklist is printed when the
Production Order is released to indicate what is needed.

Stored & Consumed from the same place

Plant P84A P84A

Storage Location METR METR
Storage Type N/A No Transfer needed. N/A
Storage Bin S09514 Non-WM pick list S09514
Prod Consumtion Sloc. N/A METR

Transferred @ IM level from WH to Line

Plant P84A P84A

Storage Location MECH FACT
IM transfer triggered by NWM
Storage Type N/A N/A
pick list
Storage Bin M03503 N/A
Prod. Consumtion Sloc. N/A FACT
Purpose / Introduction

Kanban by Product
3. Staging via KANBAN replenishment.
Materials that are to be managed via Kanban are setup to be consumed from
the KANB SLoc.
They have ‘control cycles’ setup that indicate how many Kanban containers of
the material are in the Kanban area, the quantity of the material that is held
in these containers, and how stock is replenished for these containers.
When the containers are flagged as empty via WM Kanban board, Transfer
Orders for the replenishment qty are generated to top them up.

KANBAN replenishment

Plant P84A P84A

Storage Location P84A KANB
Storage Type 020 Replenishment Transfer N/A
Order
Storage Bin A05112 N/A
Prod Consumtion SLoc. N/A KANB
Purpose / Introduction

Kanban by Product
Setting up Kanban replenishment staging by product can be done
after configuration changes by updating the SLoc on line items
within the BoM of a Product to KANB. As a result the consumption
Storage Location assigned during Production Order creation from
that BoM only would have KANB on the lines updated.
Process Map

The End to End Execution Process map is linked here -

http://libraries.ge.com/download?fileid=718449307101&entity_id=
55408743101&sid=101
The main areas of focus within this map where staging is relevant is
as shown below.
Types of Master Data Setup & Prioritisation

There are 3 areas of Master Data that Production Order look to when assigning
Issue Storage Locations on Line Items for consumption
Types of Master Data Setup & Prioritisation

1) BoM Line Item Prod.

Issue SLoc

By default, BoM Lines do

not have an Prod. Issue
SLoc.
If maintained, this will take
priority on Production
Orders.
Types of Master Data Setup & Prioritisation

2) Material Master Issue SLoc

Material Master Prod. Issue

SLoc. is the main source
when creating Prod. Orders.
If no SLoc is maintained on
the BoM of the assembly,
SAP will take this as priority
on Production Orders.
Types of Master Data Setup & Prioritisation

3) Work Center / Production Supply Area Issue SLoc

Work Center / PSA SLoc. is

mandatory during setup and
is taken if no SLoc is
maintained on the BoM of the
assembly or the Material
Masters when creating
Production Orders.
Kanban Master Data setup & execution

When Materials are setup to be consumed from KANB

(either for all Prod. Orders if from Material Master or for a
specific Product if from a BoM), they need to be setup in
WM to be staged in this way.

• Each material that is to be used within the Kanban

process must have a Control Cycle set up for it.
• The control cycle determines, among other things,
how many Kanban containers of the material are in
the Kanban area, the quantity of the material that is
held in these containers, and how stock is replenished
for these containers.
• Use transaction PKMC to create / change / display
Control Cycles
Kanban Master Data setup & execution

• To use Kanban successfully, the material that will be used in the Kanban
process must be extended to the KANB SLoc (pre requisite to be able to
create the control cycle).
• To extend/create a material within the KANB storage location you can use
transaction MMSC

Within MMSC enter the material you wish

to extend to the KANB storage location
and the Plant that this material is held in.

Press to move to the next screen.

Kanban Master Data setup & execution

The next screen will list all of the storage locations within your selected Plant where
that material currently exists.

To create it in the Kanban storage location, enter KANB as shown and click on to
save your changes. Once saved, the material will now exist in the KANB storage
location.
Kanban Master Data setup & execution

Within PKMC enter the plant you wish to

create / change /display the Control Cycle
for and click on the execute button as
highlighted
Kanban Master Data setup & execution

You will now see a list of all of the

existing control cycles.

If you wish to create a new control

cycle (as you have a new material
to use in the Kanban process), the
firstly click on to change the
transaction to Create/Change.

Next create the control cycle by

clicking on

Note you can also create a control

cycle by copying another one using
the copy button
Kanban Master Data setup & execution

When you create a Control Cycle

you will get a pop-up.

Enter the material number you

wish to use in the Kanban process
and the Production Supply Area as
shown.

Press to advance.
Kanban Master Data setup & execution

On this screen enter the

number of Kanbans (i.e.
the number of Kanban
containers), and the
Kanban quantity (the
quantity within each
Kanban container).

Furthermore, select the

Stock Transfer option under
the Replenishment
Strategy tab and set the
value to 0006.

Now press Enter.

Kanban Master Data setup & execution

Some new fields will appear on

the screen after you have
pressed Enter.

At the Stor. Bin section enter the

Warehouse Number, Kanban
Storage type (610) and the
Kanban Bin (KANBAN).

Under the Stock Transfer tab

enter the main warehouse
storage location (for Berlin this is
P84A) where the Kanban stocks
will be replenished from.

Press Enter to confirm your

entries.
Kanban Master Data setup & execution

Next click on the Print Control tab and enter ‘1’ for the Print Card and a printer
in the Output Device field. These settings will determine where the Kanban
card for this material is printed.

Finally click to save and create your new Kanban control cycle
Kanban Master Data setup & execution

• The Kanban Board is the key transaction within Kanban processing.

• Within the Kanban Board you can view the current status of all the Kanban
containers, all of the materials that are within the Kanban area, the
quantities of each material that is/should be available within each Kanban
container.
• Furthermore, the Kanban Board also allows the user to start and finish the
Kanban process.
• To access the Kanban Board use transaction PK13N
• Note transaction PK13 can also be used.
Kanban Master Data setup & execution

You can view the Kanban

Board by Supply Area and by
Material. However, you can
also view the entire Kanban
area for a particular Plant.

To view all the Kanbans for a

plant, enter the Plant number
as shown and then click on
to advance to the new
screen.
Kanban Master Data setup & execution

You will now see a list of all the materials, their supply area, their Kanban
container quantities and a graphical representation of the Kanban containers.

The colour of the Kanban container indicates its current status:

• GREEN means the container is currently FULL
• RED means that the container is currently EMPTY
• PURPLE means that the container has not yet been replenished (ie it may be
new).
Kanban Master Data setup & execution

If you double click on a container

you can see additional information
on the container including:
• The Kanban ID Number
• The Material it contains
• The Container Quantity
• Its current status
• When it was last changed (date
and time)
Kanban Master Data setup & execution

If a container if found to be Empty

and therefore needs to be
replenished, then within PK13N
(single) click on the container to
highlight it and click on

A message will now appear at the bottom of

the screen telling you that the Kanban has
been processed and the container will now
turn RED to indicate it is Empty.

In the background the system will now

generate a Transfer Order to pick the
Kanban material from the Warehouse.
Kanban Master Data setup & execution

The TO for Kanban will

automatically be printed.

Note that in the future it will

be possible to transact this
TO on the RF device.

The user will now use this

print out to go and
physically pick the Kanban
items from the warehouse
and then take them to the
Kanban area.
Kanban Master Data setup & execution

The creation of the TO can

be seen within the WM
Stock Overview LS26.

Here you can see that we

are looking to pick 6 pieces
from the Small Parts Storage
type and then put them
away inot the Kanban
Interface (storage type 610).

When the TO is confirmed,

this will remove the stock
from the Warehouse and
post the stock into the KANB
storage location.
Kanban Master Data setup & execution

When the goods have been physically picked and the Kanban container has been
replenished, the user will either confirm the TO (using LT12) or can set the status
of the container back to Full via the Kanban Board (PK13N as shown here).

Select the relevant container by (single) clicking on it and press

The container will now turn GREEN indicating it is now Full. This will confirm the
open TO and will move the goods from the Warehouse to the KANB storage
location. The items will now be available for picking from the Kanban area.
Kanban by Product Setup

A header material on a particular Product may not be the BoM that

would be changed at a granular / component level. It may be that
you need to drill down into sub structured to identify which BoMs
need to be updated. Report YPP_BOM_EDIT_RPT can be used to
do this.
YPP_BOM_EDIT_RPT – BoM Explosion Report

Enter the BoM that you wish to

explode out through various levels.
Select relevant BoM Application
(YENG is for Engineering), BoM
Usage and BoM explosion
limitations (if any). Then click
execute.
YPP_BOM_EDIT_RPT – BoM Explosion Report

A report will then be produced that explodes through required BoM levels and
supplying the requested information.
YPP_BOM_EDIT_RPT – BoM Explosion Report

Filter out lines that are not relevant to the BoM

changes - e.g. text lines (Item Category T)

What remains is an explosion level by

level with a BoM to component link
telling you which BoMs need to be
Change Master relevant and which
components inside of each would be
updated within the header structure.
YPP_BOM_EDIT_RPT – BoM Explosion Report

A secondary filter on the ‘Assembly’ column as ‘not = Blank’

which will give all of the BoM headers that need to be
considered when creating the Change Masters

These assembly material

numbers will need to be used
when entering materials /
BoMs impacted on the Change
Master (P47)
YPP_BOM_EDIT_RPT – BoM Explosion Report

When it comes to changing the BoM itself you can either use
the ‘Asm’ column to indicate if the material line item is an
assembly or a component.

Or further filters can be applied

within the
YMM_BOM_EDIT_RPT to filter
on ‘procured’ materials within a
sub structure or only non ‘Bulk’
materials for example.
Kanban by Product Setup

Any changes to a BoM in SAP require a Change Master. Even minor

changes like adding a consumption SLoc to different line items.

The following pages outline how to create the Change Master in

SAP and how to use that Change Master to carry out the changes
on the BoM.
CC01 – Create Change Master

Change Number can be entered

manually, if not it will be
assigned by SAP (numerical
order)

Ensure that options

“Change Master” &
“without release key”
are chosen

Execute.
CC01 – Create Change Master
Enter the text that best
describes the changes
required. If the text is bit
lengthier, make use of the
“change Header long text”
from the “Extras” menu.

Choose the relevant “valid From”

date from the drop-down

Please Note - If the date of the

change will be taking place in the
future this should be input here also.

The BoM can then be changed with

the change only becoming applicable
on the valid from date on the Change
Master

Choose the change no. Then Choose the tab

status as “01 – Active” “Object Types”
CC01 – Create Change Master

Choose the indicators ‘Active”

and “Object” against the
required objects (say BOM or
Material),which will allow the
system to list the required
tabs.

Choose the tab “Objects” to

enter the name of the object
that need to undergo a
change.
CC01 – Create Change Master

Choose relevant tabs for the

objects that need to undergo a
change (In this case it is ‘Mat.
BoM’)
Enter or choose the object
name

Enter the description of the Then Save to Create the

change Change Master
CS02 - Change BoM using Change Number

Use the previously

generated Change
Number in the CS02
screen against the BoM
number and press enter
CS02 - Change BoM using Change Number

The BoM Item list will

then appear. To drill
down to item details,
double click on the line
item to be updated.
CS02 - Change BoM using Change Number

In the Status / Long Text

tab, the Prod. Stor. Loc.
Can be updated to KANB.

Continue this for all line

items to be updated then
Save.
CC02 - Change BoM using Change Number

Once the BoM change is

completed, the Change
Master should be
changed to inactive
status so that it cannot
be used on a different
BoM

You do this through

CC02, Enter the Change
Master number and click
Enter.
Then while in the Header,
Change the Status from 1
(Active) to 2 (Inactive)
Kanban by Product example

In this example, most

materials on the BoM have a
Prod. SLoc. assigned on the
material masters. Some are
blank as well (for the
purposes of the example)
Kanban by Product example

How to ID impacted
materials within a BoM
to be updated
Kanban by Product example

The Issue SLoc was also

assigned on many line
items on the BoM itself.
Kanban by Product example

By default, the Prod. Stor.

Location is setup as P84A
on the PSA / Workcenter.
Kanban by Product example

Consolidated view of
master data setup and
how it gets assigned on
Prod Orders.
Kanban by Product example

Prod. Order with

assignment as expected
based on Master Data
setup.
Kanban by Product example

The material lines set up

with KANB will be staged via
the Kanban board /
replenishment process

The other materials will

be staged via YMATSTAGE
TOs or the Non-WM
method.