MFG/PRO’ eB| 70-2776A MFG/PRO eB Database: Train January 2001MFG/PRO’ eB| Kanban Sizing TRAINING GUIDE BYQAD 70-2776A MFG/PRO eB Database: Train January 2001 NM nem totapsceseseescnnnenenieThis document contains proprietary information that is protected by copyright. No part of this Soeument may be photocopied, reproduced, or translated without the prior written consent of QAD Inc. The information contained in this document is subject to change without notice. QAD Ine. provides this material as is and makes no warranty of any kind, expressed or mplied, including, but not limited to, the implied warranties of merchantabilily and fitness for a Particular purpose. QAD Inc. shall not be liable for errors contained herein of for incidental or Consequential damages (including lost profits) in connection with the furnishing, performance, OF use of this material whether based on warranty, contract, or other legal theory. Some states do not allow the exclusion of implied warranties or the limitation or exclusion of lability for incidental or consequential damages, so the above limitations and exclusion may ot be applicable. PROGRESS? is a registered trademark of Progress Software Corporation. Windows™ is a trademark of Microsoft Corporation, MFGIPRO® is a registered trademark of QAD Inc. QAD, QAD 6Q, and the QAD logo are trademarks of QAD ine All other products and company names are used for identification purposes only, and may be trademarks of their respective owners, > Copyright 2001 by QAD Inc. All Rights Fteserved, 70-27768 QAD Ine. 6450 Via Re: Carpinteria, California 93013 Phone (805) 684-6614 Fax (805) 684-1890 LeamingServices@qad.com http:smww. gad. comn/service: learn)Apour THIS COURSE . Course Description .. - 8 ‘Who Should Attend This Course 8 Prerequisites . co ee 8 8 Approximate Length of Course... Topics Covered Related Courses ee Gobaunbeeneee) Certification Preparation eT errTer 9 Using This Training Guide «000.006... . 9 Cross-Reference looms... feet dO Notes to Instructors 10 PowerPoint Slides 10 Class Kit : oe sec Configuration and Setup for This Course 2.000... in General Training Facilities Information ........... 2 CHAPTER 1 INTRODUCTION TO KANBAN SIZING...... eee ta, Course Overview oo. eee eee 4 Kanban Overview wee IS Key Elements coe 16 ‘One Card Kanban Loop . "7 ‘Two Card Kanban Loop 18 MFG/PRO Kanban Sizing Features. cere ID Kanban Users : ceeeeee . . 20 Course Objectives . 22 ~ TT err www ewe ETE eer errwrresreewre we ee - : (© Copyright 2001 by GAD ine. All Rights Reserved. FIQaDWV MEGIPRO TRAINING GUIDE — KANHAN Sizing Related Courses, 2 CHAPTER 2 BUSINESS ISSUES . ea aoe 25 Business Issues... -26 Pre-requisites... . a ‘Supplier Relationships 28 Shop Floor, Sites, and Locations 29 tems for Kanban Control 230 Maximum Demand <3 Kanban and Material Flow 32 Review 233 CuapTeR 3 Set Up KANBAN SIZING . . eee eee) Set up Kanban Sizing . 36 Kanban Sizing Setup 37 Set up Generalized Codes : 38 Generalized Codes Maintenance . 39 Exercise: Define Generalized Codes ...... - woe 40 Set up Planning Periods . a2 Planning Period Maintenance 4B Exercise: Define Planning Periods Md Define the Kanban Control File 45 Kanban Control File . 46 Exercise: Define Kanban Control File . veeAT Set up Kanban Data for Controlled Items 48 Kanban Data Maintenance 49 One Card Kanban Loop. ‘Two Card Kanban Loop Exercise: Define Sites and Locations Exercise: Define Kanban Items : Exercise: Create Kanban Product Structures... mee eso Exercise: Define Kanban Data . 60 Deleting Kanban Records. 63 Sel up Maximum Demand 64 FIQAD © Copyright 2001 by QAO ine. Al Rights Reserved.Contents Vv Maximum Demand Maintenance... . 2 65 Exercise: Define Maximum Demand. Fi +. 66 CHAPTER 4 PROCESSING KANBAN SIZING. . . Process Kanban Sizing 70 Kanban Processing cee oe .7 Caleulate Maximum Demand n Maximum Demand Calculation 73 Calculation Close-up ™ Exercise: Calculate Maximum Demand . we TS Calculate Number of Kanban or Quantity per Kanban ........0.5 78 Kanban Card Size/Print .... : ceveeeereeee 19 Number of Cards Calculation 80 Quantity per Kanban Calculation . 81 Print Kanban Cards 2 Kanban Card Size/Print 83 Sample One Card Printout sevens 84 Sample Two Card Printout we 85 Sample Audit Trail Output feces 86 Exercise: Print Cards and Audit Trail ee Exercise: Change Current Demand Pattern . seve OL Exercise: Recalculate Card Size 1 Exercise: Update Kanban Data... : cee D4 Exercise: Recalculate as Simulation 94 All Kanban Sizing Menu Options : 5 96 Summary of Generalized Codes : cece OT GLossaRY ....... eee eee oo) INDEX . . 1 by QAD Inc. Al ight FraaDVi MFG/PRO TAAINING GUIDE — KANBAN SIZING FIaan © Copyright 2001 by QAD Ine. All Rights Reserved RHE ee eee eeenewewelLLL About This Course8 MFG/PRO Traine Guine — Kanaan SiZiNG. Course Description QAD designed this course to cover the basics of preparing to implement Kanban Sizing in MEG/PRO eB. ‘The course includes: + An introduction to Kanban Sizing + An overview of key business considerations, + Setting up Kanban Sizing + Processing Kanban Sizing, + Activities and exercises Students learn how to: + Analyze some key business decisions before setting up Kanban Sizing + Sct up and operate Kanban Sizing Who Should Attend This Course + Implementation consultants + Members of implementation teams + Key users Prerequisites + Initial MPG)PRO Setup taining course + Basic knowledge of how MFG/PRO is used in the business + Working knowledge of the manufacturing industry in general Approximate Length of Course * This course is designed to be ught in 1 day Topics Covered Set Up ~ Generalized Codes = Planning Periods FAQAD © Copyright 2001 by QAD Inc. All Rights Reserved, w ww w w w w w w w w ‘we és oe o o oeAsour Tris Course 9 = Kanban Control Fit ~ Controlled Items = Maximum Demand Processing Zalculating Maximum Demand Number of Knaban or Quantity per Kanban ~ Print Kanban Cards Related Courses + Shop Floor Control + Work Orders + Inventory Control hase Order Management Certification Preparation This course is one of several courses designed (o assist students in preparing for QAD certification, examinations. However, QAD does not guarantee anyone a passing grade as a result of having aken this course. Students preparing for certification examinations should study all available materials (user guides, training guides, on-line help, for example) and acquire industry and field experience. Using This Training Guide bers of implementation teams, and operators can use this guide ban Implementation consultants, in instructor-led classes, while knowledgeable consultants who want to learn about the Sizing can use this guide for self-study. This training guide provides a road map for instruction and learning, 1t contains: + Annotated PowerPoint slides for instructors + MFG/PRO screens annotated for instructors to demonstrate the module’s functionality + Exercises and stu y questions ‘© Copyright 2001 by QAD inc, Al Rights Rest rlaaD10 MFG/PRO Traine Guide — KANBAN SIZING. Cross-Reference Icons Additional Information ‘Training Exercises ‘Phe following icon indicates appropriate places for students to work on (raining excreises: és, Notes to Instructors PowerPoint Slides QAD created the slides using Microsoft® PowerPoint ® 97, Instructors may want to animate text, graphics, and other objects on the slides to + Focus on important points + Control the flow of information + Ad wrest and variety to the presentation Clicking on Animation Preview on the Slide Show menu previews animation of text and objects “To customize slides, click on Custont Animation on the Slide Show menu PowerPoint Slide loons Informs instructors that another slide follows. Dircets students to training exercises. FAQAD “© Copyright 2001 by QAD Inc. All Rights Reserved. aa a a aTuis Course 11 Class Kit Kit for Students + Kanban Sizing Training Guide, 70-2776, + MFG/PRO eB US GUT demo CD, 10-0631 = Install the Database: vain for the exercises inthis training course Se study students will require the following additional materials: + MF Fulfillment, and electron PRO User Guides (printed material and compact disk are available from QAD available on the QAD website) copies are ~ Kanban Sizing User Guide, 78-0435 Kit for Instructors ‘The instructor kit is the same as the student kit with the addition of the PowerPoint slides. Configuration and Setup for This Course Por hardware requirements, refer to the Readme files on the MPG/PRO demo C ‘© Copyrignt 2001 by GAD A Rights Reserved. FRQAD12 MFG/PRO TRAINING GUIDE — KANBAN SIZING Telephone/Fax Class Hours Emergency Messages Breaks ale ( ' .| af | I y eee Restrooms Parking ‘smoking General Training Facilities Information FIaaD “Telephone or fax Messages Restrooms ‘Class hours: start and finish times, and punctuality Breaks: frequency, approximate times Parking considerations; carpooling ergency procedures: location of first aid, contact person for assistance Exit locations, building hours Location of approved smoking area fceeeacee eee ee ee ee w © Copyright 2001 by QAD'Ine. All Rights Reserved, soonestCHAPTER 1 Introduction to Kanban Sizing44 MFG/PRO TRAINING GUIDE — KANBAN SizinG Course Overview Introduction to Kanban Sizing Business Considerations Set up Kanban Sizing Process Kanban Sizing . Course Overview This course is designed to present Kanban Sizing in four sections: + An overview introduction, to provide an initial acquaintance with the issues and topics of Kanban Sizing + The business issues and considerations that need to be in place before using Kanban Sizing + How to set up and prepare to use Kanban Sizing, + How to process Kanban Sizing in your manufacturing environment Roan ‘© Copyright 2001 by GAD Ine. Alt Rights Reserved, arenesINTRODUCTION TO KANBAN SizING 15 Kanban Sizing Overview + What is Kanban? Japanese term that means “card contro!” Used to authorize production, shipment, and movement of goods Pull not Push methodology A Kanban Overview + The Japanese word kanbs n, loosely translated, means card, billboard, or sign ‘The term is often used synonymously for the specific scheduling system developed and by the Toyota Corporation in Ja = Kanban ~ This is a shift in manufactur push ls material through th process hilosophy to pull material through production rather than = Production waits for orders from customers and reacts quickly to these orders ‘© Copyright 2001 by QAO Ine. Al Rights Reserves. Copyrig y A Rights Flaap16 MEG/PRO Trane Guin — Kansan SiZiNG: = a | Key Elements | | + Standard Lot sizes 5 | OM | * May use standard containers | | | | + Single Card (kanban) per | container or lot inventory containers may return empty 2 Key Elements Some typical elements of most Kanban-controlled systems include: + Standard Jot sizes or standard containers + A single card per container + Conta movement mpty, usually as a signal that further material has been authorized for ers return & Copyright 2004 by QAD ne. All Fights Reserved FIaadInTRODUCTION To KaNBAN SizING 17 / One Card Kanban fine | >| Work Center A L—»| Storage me _| [worn Center B (watt ow —p> One Card Kanban Loop + MFG/PRO Kanban Sizing provides two methods: one card or + The illustration above shows a single-card system u ing the withdrawal principle © Copyright 2001 by GAD Ine. All Rights Flesorved. Fraad48 MFG/PRO Thainine Guibe — KANDAN SiziNG | Two Card Kanban Loop — ‘Two Card Kanban Loop «+ A two-card system has a move kanban and a production kanban FIQAD | | | © Copyright 2001 by GAD Ine. Al Rights Reserved. ametINTRODUCTION To Kannan Sizine 19 Kanban Sizing | Gi | € What can it do? | | Identify Kanban- | controlled items demand Calculate either: Quantity per Kanban | | | | | Print Kanban cards on | | Number of Kanban | MFG/PRO Kanban Sizing Features + Identify Kanban-controlled items + Maintain Kanban dat + Calculate Quantity per Kanban or the Number of Kanban + Print Kanban cards on nd ‘Some Benefits to Kanban Sizing * Reduction in WIP + Better inventory of components + Reducing paper on the factory floor Note Cannot do kanban control for alternate product structure types © Copyright 2001 by QAD tne. All Rights Reserved, FIQAD20 © MFG/PRO Traine Guine — Kanaan Sizing. Kanban Users —janjosiy Kanban Data > Inventory Control Supervisors and Clerks, eee a — Set Current Demand Pattern, —_—_____ en ~ Review/Modity =e |Sanban Data Maintenance fan/Validate and Calculat® Maximum Demand << Print Kanban Cards Print Kanban Cards Review Demand for Kanban Controlied items, ‘Materials Manager om late Maximum Demand & - ewew dard Data "> “eC Reprint Cards & Assembly) eee Gonnectes 4 ——— Kanban Suppliers. Review Demand _ Revowe and Fil Orde = anally Superior Run Simulations Kanban Users + Some typical users of Kanban include: = Inventory Control Supervisors and Clerks ~ Materials Ma gers ~ Assemt ~ Production Control and Manufacturing Supervisors ~ Connected Kanban Suppliers + ‘Typical tasks for each user are illustrated above Reap {© Copyright 2001 by QAD Ins, All Fights Reserved sas sagtINTRODUCTION TO KANBAN SizING 21 Course Objectives . In this class you learn how to: * Identify some key business | considerations before setting up Kanban | Sizing in MFG/PRO | + Set up Kanban Sizing in MFG/PRO * Process Kanban Sizing in MFG/PRO Course Objectives ‘© Copyright 2001 by QAD Inc. Al Rights Feserved. Foap BEERERERERRERERREREELLE LEE REAR EEDA R? |22 MFG/PRO TRAINING GUIDE — KaNBaN SizinG pe | Related Courses Work Orders Shop Floor Control CD = Prerequisite Courses, Related Courses FIQAD Inventory | Controi Kanban Sizing }, Purchase Order Management Initial MFG/PRO. © Copyright 2001 by QAD ine. All Fights ReservedINTRODUCTION To KANBAN Sizing = 23. Course Overview Introduction to Kanban Sizing * Business Considerations * Set up Kanban Sizing * Process Kanban Sizing @ Copyright 2001 by GAD inc. Ail Fights Reserved road24 —MFG/PRO TRAINING GUIDE — KANSAN SIZING. FIaad ‘© Copyright 2001 by GAD Ine. All Rights ReservedCHAPTER 2 Business Issues26 MFGIPRO TRAINING GUIDE — KANBAN SiziNG Business Considerations in this section you learn how to: | | _ Business Issues | Identify some key business considerations before setting up | Kanban Sizing Roap © Copyright 2001 by QAD Ine. Al Hights Reserved. lgegeececceceeeeceeeeecececeeeeeeeeecel eaeBusiness Issues | Business Considerations Before you set up and use Kanban Sizing, it is assumed you have already considered the following: | * Supplier Relationships + Shop Floor, Sites, and Locations * Which Items to be Kanban- | Controlled | | | + Maximum Demand for independent-Demand Items Pre-requisites + The: veral pre-requisites to using at detail ‘anban Sizing, which are only highlighted in this, issues must before you ean use Kanban Sizing © Copyright 2001 by GAD Inc. All Rights Reserved 27 fully addressed in your manufacturing environment, and in MEG/PRO, Fiaad28 MEG/PRO Trainin GuIDE — KANBAN SIZING | Supplier Relationships | | * Suppliers must be already fully set up | j in MFG/PRO before assigning them in | Kanban Data | Supplier Relationships Kanban items necd consum' supplying relationships. Any Kanban-connected suppliers database, must be alrea Setup Implications + Supplier Data Maintena Rasp © Gopyrigit 2001 by QAD Ine, Al Rights Reserves.Business Issues 29 Shop Floor, Sites, and Locations ———.—-——_ * Shop Floor Pre-Defined | Consuming and Supplying Sites and Locations must be already set up in MFG/PRO. Setup Implications + Site Maintenance 1.1.13 + Location Maintenance 1.1.18 {© Copytight 2001 by QAO ine, All Rights Reserved roan30 MFG/PRO TRAINING GUIDE — KANSAN SizING i | items For Kanban Contol * Kanban signals assume pensar) there is firm demand pulling is rnost useful in a steady demand environment. . the material. Kanban control | be processed with Kanban. | * Select which Items need to | items for Kanban Control Kanban defined in 1s moved based on firm demand. The items you select for Kanban control must be pre database, Setup Implications + Hem Master Maintenance 1.4.1 + item Data Maintenance 1.4.3 Roan {© Copyright 2001 by GAD Inc. Ali Rights Reserved,Business Issues 31 | | | | Maximum Demand * Maximum Demand is decided for Kanban-controlled independent-demand items (finished goods or service items) This is not “forecasting” maximum, but the highest | demand you are likely to experience or that you want | your system to be able to handie | re i / | * Kanban is best used in a steady demand environment Maximum Demand Kanban items need a maximum demand figure for sizing calculations. ‘This data should be determined before completing Kanban setup. Setup implications + Maximum Demand Maintenance 17.22.10 ‘© Copyright 2001 by QAD Ine. All Rights Reserved. Freap32 [xan | | - | | | MFG/PRO TRamnine Guide —~ KANBAN SIZING Kanban fod Material Flow | | | | meee ener n een { Purchasing (waste nc Kanban and Material Flow ‘The above illustration shows typical din wns of both the material and kanban flow in manufacturing, Some setups may not use every flow illustrated. Faad {© Copyrgit 2001 by QAD tne. All Rights Reserved. asn2e2ese22eetefeette HR| Review + Processes and Procedures + Reporting Requirements + Customer Expectations | + Product Configuration titt3h39144 QOVUTEEEETETETTTITIT STIG Review © Copyright 2001 by QAD Ine. All Fights Resorved. eamarresenmmir Business Issues 33 FRQAD34 MFGIPRO TRAINING Gulne — KANBAN SIZING FIQAD Course Introduction to Kanban Sizing | Business Considerations Set up Kanban Sizing Process Kanban Sizing | cece eee CeCe Cee Cee eee TET eeeeeee {© Copytight 2001 by OAD Inc.All Rights Reserved.CHAPTER 3 Set Up Kanban Sizing36 MFG/PRO TRAINING Guibe — Kanaan Sizinc © ; . | Set up Kanban Sizing In this section you learn how to: Set up Kanban Sizing in MFG/PRO — Set up Kanban Sizing {© Copyright 2001 by GAD Inc. Al Rights Reserved. Faad CCC CCC CHEECH HEE KCECE CEC ECECCEEEEEEECE 3 4SETUP KANBAN SiziNG 37 Set up Kanban Sizing | Set up Generalized Codes Set up Planning Define Kanban | | | | | | | Periods Control File Set up Kanban Data for Controlled Items Set up Maximum Demand Kanban Sizing Setup This illustration is a suggested setup sequence of master files for the Kanban Sizing module which is based on information that flows from one master file to another and prerequisites that need to be accomplished before setting up a file, Reading the illustration: {© Copyright 2001 by GAD Inc. AB Rights Reserved. Roan saeveaeennrn 338 MFG/PRO TRAINING GUIDE ~ KaNaAN Sizino neces! Generalized Codes Set up Generalized Codes Generalized Codes give you flexibility in organizing and implementing functions, since you can define values that are-medaingful in your own business environment \ FIQAD © Copyright 2001 by GAD Ins, Al Rights Reserved,BREET hhh HHA dH Th, | SeT UP KANBAN SIZING 39 36.2.13 — Generalized Codes Maintenance Demand Patterns (kbmd_pattern) + Used to refiect trends or cycles +_Only one demand pattern will be active at a time Kanban Types (knb_type) Used for reporting purposes Container Types (knb_cont_type) + Information only Generalized Codes Maintenance Menu Number 36.2.13 * You can create as many Demand Patterns as you like, but anly one demand pattern is active at atime © Copyright 2001 by GAD ine, Al Rights Reserveo. Raap40 MFG/PRO TrAININ GUIDE — KANBAN SIZING Setup Exercises | | Important The data used in these exercises may not be the same as the data shown in the screen captures in this lesson, Exercise: Define Generalized Codes Description: In this exercise, you define generalized codes. 1 Set up one kanban type code, using the following values. Use Generalized Codes Maintenance, 36.2.13 Field Data Field Name knih_type Value west Description test kanban type mean ve, Al Rights ReservedSET Up KaANBAN SIZING 41 2 Sct up one container type code, using the following values: Field Field Name Value basket Description basket container type 3 Sct up two demand patterns, using the following values: Data Name komd_partern Value summer Description summer demand pattern Field Data Field Name komd_pattern Value winter Description winter demand pattem © Copyright 2001 by OAD Ine. All Hights Reserved roap PreemieCLECCCCECCCECECCCEECCEECEELEEE 42 MFG/PRO TRAINING GuIbe — KANBAN SIZING | | _ Set up Kanban Sizing \ | Set up Planning | Periods Set up Planning Periods + After defining generalized codes and setting up the control file, define the planning periods with Planning Period Maintenance 17,22.7 + Assign planning periods to combinations of item/consuming site/demand patterns in Maximum Demand Maintenance 17.22.10 € wi vw w aap ‘© Copyright 2001 by QAD Inc. Al Rights Reserved,SET UP KANBAN SIZING 43 17.22.7 — Planning Period Maintenance + Planning Periods are used to calculate the maximum demand per hour Description Number of hours per planning period Planning Period Maintenance Menu Number 17.22.7 + You ean sct up as many planning periods as you like Note You cannot delete a planning period associated with an existing maximum demand record. © Copyright 2001 by GAD Inc. A Rights Reserve rit ights Reserved ReadKanban SiZING. Exercise: Define Planning Periods Sass, Description: in this exercise, you define two planning periods for your production 4 Set up two pianning periods, Use Planning Period Main Field Planning, Period Description Hours Per Period Planning Period Description Hours Per Period read sing the following valu Data daily8 daily 8 hours, 8.00 daily12 daily 12 hours 12,00 {© Copysight 2001 by QAD Inc. Al Rights Reserved. ae ew ewww eee eneneoeoece1tSET Up Kansan Sine 45 Define Kanban Control File Define the Kanban Control File The Kanban Control File indicates which Demand Patiesn is used in current calculations. FRQAD46 MFG/PRO TRAINING GUIDE — KANaAN SizinG 17.22.24 — Kanban Control File ea [3] ‘User Menu Et Queve Options Help Cent Disord Patten: FEE fat Demian Pate * Current Demand Pattern will be used in maximum demand calculations and kanban sizing calculations Kanban Control File Menu Number 17.22.24 + Specify the current demand pattern Used in Maximum Demand Calculation 17.22.13 and Kanban Card Size/Print 17.22.15 + This field is validated against codes set up in Generalized Codes Maintenance 36.2.13 for field kbmd_pattem Roan © Copyright 2001 by QAD Ins. All Rights Reserved. RENSETUP KANBAN SIZING 47 Setup Exercises | Qs) — — a Exercise: Define Kanban Control File Description: In this exercise, you define the kanban control file. 1 Select the summer demand pattern, set up in the exercise above Use Kanban Control File, 17.22.24 © Copysight 2001 by GAD Ine, Al Rights Reserved. Fraap meena48 —MFG/PRO TRAINING Guide .~ KANBAN SIZING | Set up Kanban Sizing Set up Kanban Data for Controlled Items | Set up Kanban Data for Controlled Items | | | | ‘Afict setting up the planning periods and control file, you can begin entering kanban data using Kanban Data Maintenance 17.22.1 FIQAD © Copytight 2001 by GAD Inc.All Rights Reserved.ARRRRRLRRRSLRRLEDEEAAIEDIIDITIIAIIIN | SETUP KANBAN SzING 49 17.221 ~ Kanban Data Maintenance Unique Key 5 Fields: tem Number and Defining the ‘Supplying anc Consuming Relationships Metliiy Factor 289 Celt yas f Cade Kanban Waximin Denand Bata ae Deane Potten: Fall Fall Demand Paton Max Demand per Hour 6-25 One = Prints a Single Card Kanban Data Maintenance Menu Number 17.22.14 tem Number + Cannot have the Pur/Mfx Code of F (family) in em Master Maintenance 1.4.1 + Cannot be a global phantom for either the item site 0 pt _phantom cannot be Yes) Replenishment Time * Includes all relevant components of lead time and required slack time -m master (ptp_phantom or ~ Slack time is used for any producing cell that produces more than one item + This field is a contract between supplying and consuming sites, reflecting maximum turnaround time © Copyright 2001 by QAD Ine. Rights Reserved. Rraap