Kanban Pull Sequence and Kanban Cards

Kanban
Kanban is a means of supporting pull-based replenishment in manufacturing
systems.
A Kanban system is a self-regulating pull system that leads to shorter lead
times and reduced inventory.
Kanban systems are typically applied to items that have relatively constant
demand and medium-to-high production volume.
Kanban represent replenishment signals that are usually manual and highly
visible, such as a color-coded card that moves with the material, a light that
goes on when replenishment is required, or an empty bin that is moved to
the supply location to trigger replenishment.
The four types of Kanban available in the system trigger transactions that
pull material from different replenishment sources.
1.
2.
3.
4.

Inter-Org Transfer Replenishment through IR ISO

Intra-Org Replenishment through Sub inventory transfer.
Production Replenishment through WIP Job.
Supplier Replenishment through purchase from external supplier.

Pull Sequence
A pull sequence is a group of information that defines a Kanban location,
source information, and planning parameters for an item.
An item can have multiple pull sequences that make up a replenishment
chain
Pull sequences are used to calculate the number or quantity in each Kanban
container at that location.
A Kanban location can be a sub inventory or an inventory locator.
Important Pull Sequence terms
Planning Only Flag Program Will Perform Kanban Calculations. User Can
Manually Execute Kanban sequence. User cannot generate and print Kanban
cards or execute the replenishment cycle.

Kanban Size and Number of Kanban Cards Kanban cards are

functionally containers .Kanban size is number of items in each Kanban
container.
Minimum Order Qty -- This is used when calculating Kanban size or during
the Kanban execution process to aggregate Kanban smaller than the
minimum order quantity. This Field defaults from item master which can be
overridden.
Replenishment Lead Time --This is how long it will take to physically
replenish the Kanban.
Production Kanban use the replenishment lead time to calculate the size of
the Kanban but use the Lead Times on the Item Master window to determine
when to schedule jobs created by replenishing the production Kanban
Supplier and inter-org Kanban use the replenishment lead time to calculate
the size of the Kanban and to schedule the "need date" for the purchase
requisition
Incase Lead Time is Left Blank Kanban will use the lead time defined in the
Item Master window for the "need date" on the requisition. (Need date =
sysdate + pre-processing + processing + post processing time if the
replenishment lead time on the pull sequence is left blank.)
Allocation Percent -- The allocation percent represents the percent of
independent demand for the Kanban item that is to be supplied from this
pull sequence.
Lot Multiplier -- When Kanban planning sizes the containers at the location,
it will size in multiples of this quantity ex if Fixed Lot Multiplier is 10 and
Requirement is 15, Kanban Will Generate a card for 20
Safety Stock Days -- Safety Stock Days is the number of days demand
that will be added to the Kanban for safety stock.
Kanban Chain: Kanban Chain is a series of pull sequences that model the
replenishment network on the shop floor. Example Sub inventory Transfer to
Stores, Stores to Supplier.
Kanban cards are created for an item, sub inventory, and locator.
Card Status
Kanban cards are generated with a default Card Status of Active.

If the Supply Status is full, we can temporarily pull a card out of the
replenishment chain by changing the Card Status to Hold.
We can stop the usage of a card by changing the status to Cancelled Which
Cannot be made Active or Hold Again.
A Cancelled Card can be deleted.
Supply Status
All the following Supply Status codes can be set either manually or
automatically.
New --The Kanban has just been created and is not yet part of the
replenishment chain
Empty --The Kanban is empty and a replenishment signal has been
generated (available only for Inter Org and Supplier source types).
Full -- The Kanban has been replenished.
Wait -- The Kanban is waiting until the minimum order quantity has been
met by the aggregation of cards.
In-Process -- For the Supplier source type, the purchase order has been
approved. For the Inter Org source type, the internal requisition has been
approved.
Non-Replenishable Kanban
Non-replenishable Kanban are used to meet unexpected peaks in demand.
For demand variations that are infrequent and unplanned, Oracle Flow
Manufacturing allows non-replenishable kanban cards.
These cards are created for specific items in specific quantities as needed.
Non-replenishable kanban cycle through the system only once, after which
they are removed from production.
Points to Note While Creating Manual Kanban Cards
Replenishable and Non Replenishable KANBAN Cards Can be manually
generated.

Replenishable KANBAN Card Can be Manually Created Only with Reference to

Pull Sequence .
Cards can be created in EMPTY, FULL and NEW Status.
Tables Involved
1. For Pull Sequence --MTL_KANBAN_PULL_SEQUENCES
2. For Kanban Cards -- MTL_KANBAN_CARDS
3. For Kanban Activities -- MTL_KANBAN_CARD_ACTIVITY
Views
1.For Kanban Card --MTL_KANBAN_CARDS_V
2. For Kanban Pull Sequence --MTL_KANBAN_PULL_SEQUENCES_V