Setting up Kanban suggestions


(Brandon Anderson) #1

It looks like Kanban receipts only work for BOM’s with one level, unless the child parts are set a Phantom BOMs (which basically makes it only one level anyways). Is that a correct assumption? Basically no sub-assmblies in Kanban receipt jobs.

Another question about Kanban receipts. If I start setting up some parts with Kanban bins, (part>site>warehouses>bin information>detail, replenishment type or part>site>warehouses>detail, replenishment type). Will that have any effect on other areas of the system? Or is it only going to add the lines into the Kanban Bin Monitor.

We don’t currently use any of this, but is looks like it could be a simpler way for us to put some stock parts on the shelf and handle some basic parts orders. Does anyone else have experience with the Kanban system? Good or bad?


(Ernie Lowell) #2

That’s exactly what Kanban Receipts was designed for. When used as designed, it’s great!. I’ve installed the process several times, and it’s more of a “process issue” than a real Epicor problem. Here we are telling people to make sure they log every transaction and count each piece and document every single step… except for now when the system does it all for you (just make sure you do it RIGHT!)

Half the time though, people still want to print out a traveler for a Kanban Receipt. Oh well. I LOVE Kanban Receipt and wish more places would use it.


(Brandon Anderson) #3

Yeah, that’s what I’m worried about. When to use this, and when to not. We aren’t good at process definition here, it’s lot of “just ask when it comes up”. Then they wonder why simple things seem to take so long.

Anyways, It looks like once the BOM starts to get very complicated it doesn’t let you use Kanban receipts, which is good. I was thinking about writing a BPM to do that anyways, but it looks like I don’t need to.

That’s one of the things I am a little worried about, which is, how does someone know what they need to do? That’s where we have to explore some things like static binders that have prints in them or something like that.


(Ernie Lowell) #4

It’s designed for simple items that can be built quickly and in volume, frequently while other things are also running. It is NOT designed for complex parts that an operator would need detailed instructions about. Think about something like a bracket assembly that needs some rods, hinges, screws, and maybe a spring or two. Takes an experienced operator maybe a minute apiece, but since you go through them like water, you ALWAYS need more. Using a Kanban Receipt process for this means you can tell your operator that you need 50 by the end of the day, and when he/she gives you the box of 50 you do the Kanban Receipt and BOOM. The job is opened, completed, and closed, all the materials and labor and burden are costed.

If the part is more complicated than that, it shouldn’t be a candidate for Kanban Receipt.


(Tim Shoemaker) #5

Kanban should be reserved for assemblies that have a single operation (or multiple operations that are completed all at once). Examples I have personally seen where it totally made sense:
1. Brick Manufacturer: Company made bricks… they would decide at the beginning of each day how “Long” (duration) to run the batch of bricks… they never really knew the total yield, nor did they care too much. They would run it for 6 hours, constantly reloading the cement hopper, and when done, they simply counted how many got finished. At that point, they did a Kanban Completion, and the system automatically backflushed the approximate amount of “Ingredients” according to their “Recipe” (the BOM).
2. Door manufacturer: they made doors & Door Frames… to make a door, you needed side rails, top rails, bottom rails, etc. These rails were cut from standard extrusions of multiple standard colors. The DOOR was not the kanban item… but the RAILS were… Someone would look in their mobile Kanban Bins, and see that they were running low… They would go to the uncut stock, and cut enough to fill the bins. They did this with a Kanban completion. into the bins. Then as doors were completed, they backflushed the rails.
3. Pool Pump Manufacturer: They purchased Motors, They made housings (on regular jobs), but had alot of other accessory items such as power cords. When the accessory items got low, a bin went back to the accessory assembly area… they would make enough power cords to fill the bin, and then do a KanBan Completion. The finished Pumps (with housing and powercords) were made on regular backflushed jobs.