KANBAN INTERMEDIATE PHASE V0.pptx

ARP Change Management Training
Kanban– Overview, Create, Monitoring & Execute Kanban Loop
(Study case of Transfer Intermediate Phase PGI  PEA)
Lesson ID: ARP_EN_DIP_SCL_L51

© AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.
Agenda Transfer Intermediate Phase (PGI --> PEA)
•Overview (cf. ARP_EN_DIP_SCL_L51_Kanban_Create_Kanban_Loop.pptx )
•Creation (cf. ARP_EN_DIP_SCL_L51_Kanban_Create_Kanban_Loop.pptx )
•Execute (cf. ARP_EN_DIP_SCL_L70_Transfer_Intermediate_Phase_Nominal_Flow_and_Kanban_modif_V.1.pptx )
•Return Flow (cf. ARP_EN_DIP_SCL_Secondary_flow_Kanban_Materials_V1 0.pptx )
•Monitoring (cf. ARP_EN_DIP_SCL_L53_Monitor_Kanban_Loop.pptx )

Kanban Loop
Definition
• A Kanban loop has one or several cards, sized to cover the needs for nominal routing of
Kanban station.
Kanban loop is dedicated to one material.
• When a loop is initiated, it is launched when the first need of replenishment is triggered.
• The Kanban replenishment area defined the Kanban loop for one material dedicated to
specific needs. These needs are physically available for the consumer in an area already
determined with him.
• Computational Kanban loop creation is launched after Ordering Officer validation
(prerequisite whatever the flow, S-K or S-W-K):
- Kanban flow (workability analysis according to the flow relevance)
- Replenishment strategy retained
- Loop dimensioning (card quantity, bin quantity, unit of time to coverage the loop need)
- Planned date creation

Transfer intermediate Phase (TIP)
Definition
The transfer intermediate solution concerns the physical stock transfer of materials between two storage locations in
two different systems within the same company code (within the same country).
The cross-system is the mechanism by which a stock is transferred from one storage location to another storage location
in two different systems.
Cross-system stock transfers are used as back-up solution when the stocks of the ordering plant A cannot cover its
needs, whereas another ordering plant of the same company code has available stocks for the same article. It pre-
supposes that the article is ordered by different plants. This is the case only for fasteners and hardwares.
The solution can also be used for kanban intermediate flows.
Cross-system stock transfers:
 are forbidden within the same ordering plant for manual requests,
 are allowed within the same ordering plant for kanban intermediate.
 are allowed in different ordering plants.
Main flows :
 Transfer between 2 Sites, from ARP to NatCo FR - Manuel Request
 Transfer between 2 Sites, from NatCo FR to ARP - Manuel Request
 Transfer between 2 Sites, from NatCo FR to ARP - Kanban Replenishment
 Transfer within the same site, from NatCo FR to ARP - Kanban Replenishment
To cancel a transfer:
 Create a manual request in the opposite direction.
Click on for more details
This solution must be applied for kanban
intermediate in-situ, that is to say when:
 the kanban loop is in ARP
 and the material main stock
belongs to a migrated plant, but
it is not managed in ARP

ARP
Nominal Flow KANBAN TIP Natco  ARP
A-F Legacy system
Purchase requisition
& reservation
Purchase order
Sales order
Outbound delivery
Goods issue on OD
Goods receipt
In-transit storage location
Transfer
from in-transit storage location
to kanban storage location
Transfer Request
Prepare & picking
TO
MIGO
Transfer posting
Reservation - 311
Manual action
Automatic action
1
2
3
4
5
6
7
8
9
Closes PO
Kanban set to full
Closes
reservation

© AIRBUS S.A.S. All rights reserved. Confidential and proprietary document. Page 7
14
Nominal Flow KANBAN TIP Natco  ARP

Process steps
S2 Define supply area
S3 Define Kanban loop
(size and replenishment
type)
S4 Define blocking
indicators
Triggering event
Scope of this training
Zoom to step
Manual action
Automatic action
Kanban solution validated
S5 Kanban card is
created
S1 Maintain material
Master Data
Create Kanban Loop
S6 Scan bin empty
S7 Apply a
replenishment strategy
S8 Monitor
Execute Kanban Loop
Monitor Kanban Loop
See Lesson:
-ARP_EN_DIP_L51_Kanban Loop
Initialisation
See Lesson:
-ARP_EN_DIP_L52_Execute Kanban
See Lesson:
-ARP_EN_DIP_L53_Monitor Kanban
Loop

Transactions used
AS IS (xGI) TO BE (xEA) Roles Effects
Kanban Storage
Location
Define account parameters of Kanban
solution : AT or UO or DIV
No effect if there are no supply area and
Kanban loop associated
ZDFCAT10 Create cost receiver of Kanban storage
location
See handbook ‘’ order creation procedure/ OTP
kanban’’
ZDMACT10
( ZM78 )
PK05
see ARP_FR_DIP_SCL_L51
Create delivery address to distribute
Kanban batch on preparation area of
the milk run
Delivery address on Kanban Delivery note
ZM82 PK05
Define Kanban supply area linked to
Kanban storage location
For every loop associated gives the link
between delivery area and account parameters
ZM15 PKMC
Declare material in Kanban solution Delivery or replenishment and Kanban delivery.
When created, there are no more TR on a WO
composant of the cost center.
Creation of a card ID
ZPK1 PKMC / ZPK17
Edit cards with Kanban barcodes
ZM11 with TCAB
PKBC by default
ZKANBAN_SCAN
PKBC
see ARP_EN_DIP_SCL_L52
Generate Kanban replenishment in the
system from a recording tool for
barcodes (TCAB)
Computational Kanban creation as a
reservation or a Kanban order or a WO
CREATE

type)
S4 Define blocking
indicators
S5 Kanban card is
created
Master Data
Create Kanban Loop
S6 Scan bin empty
S7 Apply a
S8 Monitor
Execute Kanban Loop
Monitor Kanban Loop
• In-house production: the replenishment
request triggers Work Orders
• External procurement: the
replenishment request triggers a PO
(strat. Types P*) or stock transfer PO
(transfer in 2 steps, strat. Types T2*)
• Stock transfer: the replenishment
request trigger a transfer (1 step)
• Intermediate phase: solution of stock
transfer for Kanban loop in ARP and
Stock in Legacy and vice versa. (T11x)

S0 Kanban loop data creation
Master data view creation
Kanban Intermediate phase (PGI -> PEA)
 Stock in Legacy Create material master :
 MRP 2 view : MRP-indicator = « 1 » (Independant requirement); check ATP-check =
« KP »
 Create Storage location view; check / maintain storage condition in storage location
view (link to main warehouse) : ensure that TVKOL is filled for Storage condition,
plant and shipping point.
 Storage location cross-ref must be done in PEM.
 Batch management has to be the same in both systems.
 Requests on NSPI for each material has to be created or updated.
 Sales view on sales area FR99/99/99 and on the supplying plant is created
automatically from table ZDPGAT_DATA_SV (transactions ZDPGAT_DATA_SV)
 Loop in ARP Create material master :
 MRP 4 view : MRP-indicator = « 1 » (Independant requirement); check ATP-check
(MRP 3 view) = « Z2 »
 Create Storage location views of Kanban SL + transit SL
 Purchasing view on the receiving plant is created automatically from table
ZDPGAT_DATA_PV (transactions ZDPGAT_DATA_PV )
 field "Plant-sp. matl status" of "Purchasing" view must be BLANK.
 In case of QM key active at master data level, the “procurement key” must be
defined : Create QM view based on the Provisionning plant.
 At GR posting, the mandatory characteristics of the material batch are filled
automatically with a default value from table ZDPGAT_BATCH_CHA (transaction
ZDPGAT_BATCH_CHA)
Create Kanban PSA (module), if needed
Create Kanban Control Cycle (replenishment strategies T111 – T113)

S1 Create Kanban Loop
Material Master Data (1/2)
 Transaction MM01
On the initial screen enter a material
number
Enter or validate
Click on the icon to select all the views
and validate
Enter plant and storage location
Validate
2
1
3
4
5
1
4
5
3
2

 Transaction MM01: Create Data
Material Master Data (2/2)
1
2
2
Check that the “plant data / storage
location” tabs have been created
In the “MRP4” tab check the Sloc MRP
indicator field
2
1
Remark:
Storage location MRP indicator is 1 because
Kanban Storage location should be excluded
from MRP (only for stock transfer and external
procurement)
No MRP indicator for Manufactured kanban

Supply area (1/2)
 Transaction PK05: Update existing entry
SAP Supply areas represent physical Kanban rack. A supply area may represent one or several Kanban
racks. This address is the Distribution address. It will be printed on the delivery document to know where to
deliver the goods
1
Enter Plant and Accept
Select a line and click on Details
Click on Address
Complete and Accept
2
1
3
4
4
2
3

Supply area (2/2)
 Transaction PK05: Create a copy from an existing entry
1
2
Enter Plant and Accept
Select a line
Click on “Copy as”
Modify data: Storage Location, Supply Area,
Plant, Responsible and/or Unloading Point
Enter or Validate
Save
2
1
3
4
5
Remarks:
It is also possible to
create also new entries
by clicking on the button
“New Entries”.
3
6
4
5
6

type)
S4 Define blocking
indicators
S5 Kanban card is
created
Master Data
Create Kanban Loop
S6 Scan bin empty
S7 Apply a
S8 Monitor
Execute Kanban Loop
Monitor Kanban Loop
• In-house production: the replenishment
request triggers Work Orders
• External procurement: the
replenishment request triggers a PO
(strat. Types P*) or stock transfer PO
(transfer in 2 steps, strat. Types T2*)
• Stock transfer: the replenishment
request trigger a transfer (1 step)
• Intermediate phase: solution of stock
transfer for Kanban loop in ARP and
Stock in Legacy and vice versa.

Kanban loop
 Transaction PKMC: SAP control cycle represent physical Kanban loops
Enter Plant (mandatory)
Click on the “Change->Display” button to
toggle between the modes
 User has to click on that button so that the
button for “Creation” appears
Click on create
Choose option “Classic KANBAN”
Enter Material and Production Supply Area
Accept
2
1
3
4
Remarks:
The material master view must be created for the Kanban storage
location linked to the supply area to allow the creation of Kanban loops.
 Kanban loop has to be created on the ordering plant (« specialist »), and
not on the fitting plant (« geographic »)
5
3
1
4
5
6
Click this button “Extended
selection for more selection
criteria
6
2

Kanban loop
 Transaction PKMC Enter:
Supply area
Storing Position
Number of Kanbans
Quantity per Kanban
Choose Replenishment Strategy type (further
details next slide)
Enter the theoretical duration in number of days
Press Enter or Validate
 Status will change from (inconsistent) to
(consistent, not saved) as well as the
“Replenishment Strategy” tab depending on the
selected option
2
1
3
4
5
1
3
4
5
2
6
7
Update 13.1
7
6

Kanban loop
 Transaction PKMC: Focus on replenishment strategy
Study Case: Transfer Intermediate Phase (PGI  PEA)
Select the Replenishment strategy “Transfer”
validated
Enter Stock Transfer (mandatory)
Enter Storage Location (mandatory)
(Here use Transit storage location )
2
1
Tab will change
once the strategy
was chosen
1
Stock replenishment strategy:
T11X will be used when the transfer is from stock
managed in Legacy system.
Last digit meaning
Txx1: Warehouse Kanban
Txx2: Kanban WIP Flying goods
Txx3: Kanban WIP Non flying goods
3
2
3
Update 13.1
Transfer Stock Leg/K ARP/ warehouse
T112

Transfer Stock Leg/K ARP/ warehouse
T112
Kanban loop
 Transaction PKMC: Choose another replenishment strategy
If a new replenishment strategy is needed,
click the New strategy button
1
1
Update 13.1

Kanban loop – Additional Data fields
New slide
13.1
Transaction PKMC: Enter additional data fields for each replenishment strategy
Theoretical duration : theoretical cycle duration of a
Kanban loop. Mandatory field managed with a
number of days at Control cycle level.
Additional Replenishment time : lag between
replenishment request (scanning) and delivery
(requested lead time) managed at loop level (not
mandatory information)
Replenishment requested tolerance : percentage
allowing to define, at Kanban cycle definition, a partial
delivery alert level (not mandatory information)
Alert tolerance percentage : tolerance (in percentage)
to trigger the alert (not mandatory information)
1
2
3
4
1
2
3
4
These new fields of control cycle are
integrated in “Change Layout” of
PKMC transaction

Kanban loop – Flow Control / Kanban Calculation / Print Control
 Transaction PKMC: complete remaining tabs
2
1
3
4
6
5
Go to the flow control tab
Enter Status sequence 0001 (mandatory)
Go to the Kanban Calculation tab
Enter RLT (Days)
Go to the Print Control tab
Select an option and a device to print once
the Kanban is finished
2
1
3
4
5
6
6

Kanban loop - Kanban replenishment strategies
 Transaction PKMC: Print Kanban card
 Transaction ZPK17: Mass print Kanban cards
Enter Selection criteria
Click on Execute
Select the Kanbans
Click on the print button
Labels are printed
1’
2’
3’
4’
1
1’
2’
3’
4’
Click on the button to print Kanbans
1
5’
5’

Remove Kanban Loop (1/2)
 STEP 1 - Transaction PKMC: remove a Kanban Loop
After Kanban loop removal, remaining goods must be physically removed from the Kanban
racks. This physical activity must be replicated in the system
Select a line
Click on the bin
2
1
1
2

3
Remove Kanban Loop (2/2)
 STEP 2 - Transaction ZMM06M: put a deletion flag Enter selection criteria
Validate
Tick the storage location box
Save
Check the confirmation message
2
1
1
2
3
4
5
4
5

Kanban loop – Navigation profiles
 Transaction PKMC: Customize screen to add a link with other transactions using the
Navigation Profile.
Click on the button “Navigation profile”
Select option “Change Navigation Profile”
Select “Application Toolbar”
Click on the button “New Entry”
Select transaction Call
Fill in at least Text and Transaction
 Chose an icon, if desired
Click on Enter
2
1
3
4
5
2
1
3
4
6
6
7
5
7
Direct link to PK02 transaction

Blocking indicators
ALL modifications on blocking indicators (set lock or deletion indicator) have to be
done manually. At creation of Kanban control cycle, the first Kanban bin has to be
locked manually.
• Whether the bulk bin exists in the system and it is automatically blocked to
prevent its use.
• Whether it is deleted from the system and exists physically (when necessary),
which would prevent errors and dysfunction.
• When a card is cancelled, blocking are not mandatory (it is not a general rule).
Reminder: blocking card when a cancellation is needed is used as dysfunction
palliative.

Blocking indicators
WAIT
EMPTY
FULL
STOP
BLOCK
Kind of bin?
In case of
reactivation
Open bin
(bulk)
Empty/
full bin
Delete the loop
Receive parts for PO
and WO and Picking
confirmation for
stock transfer
Reactivate the
loop
Request for
replenishment
AND
In case of loop removal In case of loop removal
ERROR
Deactivate the
loop
Problem ?
Yes
No Solve the problem
Manual activities
needed to cancel
the replenishment
request

Blocking indicators
Transaction PK02: lock Kanban card
(to be done for new Kanban loop)
2
1
3
4
5
7
6
Enter:
Material
Plant
Supply Area
Click on Validate or press Enter
Click on the Kanbans button
Flag Lock indicator and validate
Save
 Then a cross will appear in the Kanban
board (PK13N)
2
1
3
4
5
6
7
Remarks:
The Blocking indicator may be added to Kanban card whatever the status is
 There are two columns in the “Delete and Lock Kanbans” window.
The “Lkln “one locks Kanban card and the “Dlnd “ one deletes Kanban card.
 Deleting Kanban card can only be done if the status is “Wait”.

Blocking indicators
 Transaction PK13N to check the locked Kanban card status
Before setting the
blocking indicator
After setting the
blocking indicator
Kanban loops being created on the Ordering plant, the
reproduction on a global scope may have to be performed in
several times (the extensive selection not being multi-sites).

Blocking indicators
Enter:
Material
Plant
Supply Area
Click on Validate or press Enter
Click on the Kanbans button
Flag Delete indicator and validate
Save
2
1
3
4
5
6
7
2
1
3
4
5
Remarks:
 Deleting Kanban card can only be done if the status is “Wait”. If not, user
must change it .
Transaction PK02: delete Kanban card
7
6

© AIRBUS S.A.S. All rights reserved. Confidential and proprietary document. Page 35
Blocking indicators
 Transaction PK13N to check the deleted Kanban card status
Before setting the
blocking indicator
After setting the
blocking indicator :
card 2 has
disapeared

3- Les différents cas d’utilisation
TIP PGI  PEA – Kanban replenishment
Page 37
14

TIP PGI  PEA – Kanban replenishment
Page 38
14
Click on every steps
Request: Kanban Replenishment (Auto)
• Via transaction
• ZKANBAN_SCAN (Upload the Mobile Device)
• PKBC (Scan empty card barcode)
• PK13N (Manual kanban replenish. Request)
• Replenishment strategy : T11x
• Receiving plant (R plant) = plant of the Kanban loop
• Receiving Storage Location = Kanban SL of the loop (K SL)
• Supplying plant = plant of the Kanban loop
• Transit Storage Location = supplying SL of the loop (T SL)
• Material code, Quantity : from the loop
• Delivery date = current date
Manual Reservation (MR) creation (Auto)
• Via transaction MB23
• From R plant / T SL To R plant / K SL
• Movement type 311
Purchase Requisition (Preq) creation (Auto)
• PReq type NB
• Purchasing group = P99
• Vendor = AI99_F*
• On R plant / T SL
• T SL address becomes the address of K SL
Purchase Order (PO) creation by conversion
of the Preq (DIP interface)
• PO type ZPO1
• Purchasing group = P99 / purchasing organization
= AI99
• On R plant / T SL (address of the K SL)
• Free item
• Output message ZSC1, for IDOC creation
IDOC creation from ARP to Natco (DIP interface) (Auto)
• Custo ALE for the message ORDERS :
o in xEA : / vendor, outbound parameters ORDERS for partners AI99_FNT1, AI99_FNZ1, AI99_FTO1, AI99_FFF1
o in xGI : from partner xEA, inbound parameters ORDERS , with process code ORDE
• Cross-referencing of the material code and BUM
Sales Order (SO) creation in Natco (DIP interface) (Auto)
• Via transaction VA03
• SO type ZTIK from table ZEDSDC / activity type TT02NF
• SO valuated, against Cost centre and WBS from table ZDPGAT_COST_OBJ (transaction ZDPGAT_COST_OBJ)
• Sold-to = ARP PO vendor
• Ship-to from table ZDMACTSHIPTO / ARP K SL
Outbound Delivery (OD) creation (Auto)
• OD type ZTKD (no more OD could be created even if the delivered quantity is not the requested quantity)
Prepare + Picking + Shipment process + GI on LV
• Via transaction VL02N (OD) & LT03 (OT)
• AS IS process – scanned document is a WM-OL or a WM-LL family (function module : ZFMTRZ01_IDENT_DOC)
• TO printed with ARP kanban information needed for the replenishment (ID, Module, Bin)
• Shipping note printed with information for the transfer (no specific transfer form) quantity
GI on OD type ZTKD (Auto)
• Via transaction VL02N
• GI valuated, against Cost centre and WBS from
the SO assignment
• The SO is completed even if the delivered
quantity is less than the requested quantity
GR IDOC creation from Natco to ARP (DIP interface) (Auto)
• Custo ALE for the message MBGMCR :
o in xGI : for partner xXA, outbound parameters MBGMCR /
GR
o in xEA : from partner xXA, inbound parameters MBGMCR /
GR , with process code ZGR
• Cross-referencing of the material code, BUM, cost center and
WBS (becomes a CO order in ARP)
GR creation in ARP (Auto)
• Movement type I01
• New entry on table ZDMSTT_KB_AUTOTR
• GR valuated, against Cost centre and CO order (cross-ref of GI assignment)
• A new batch is created in ARP, with an internal number, and the vendor batch
n° in ARP is copied from the Natco batch
• The serial numbers are the same in both systems
PO closure (Auto)
• Done in the same time than the GR
• In the PO item, the flag “delivery completed” is flagged even if
the received quantity is less than the requested quantity
Physical Delivery
Physical Delivery
Inbound process : transaction MIGO on reservation
• The flag “reservation completed” must be set manually if the receiving
quantity is less than the requested quantity
• The batch or serial numbers must be added manually in the reservation

TIP Natco FR to ARP – Kanban replenishment
Page 40
Step 1 : Request : Kanban bin is set to empty through bar-code scanning
• Input : Kanban loop
• Replenishment strategy : Stock transfer T11x
• Receiving plant (R plant) = plant of the Kanban loop
• Receiving Storage Location = Kanban SL of the loop (K SL)
• Supplying plant = plant of the Kanban loop
• Transit Storage Location = supplying SL of the loop (T SL)
• Material code, Quantity : from the loop
• Delivery date = current date
• Other input through a specific table ZDSCLT_VENDOR
• Vendor AI99_F*
• Automatic Output :
• Determination of the activity type TT02
• Step 2 to 4
Step 2 (Automatic) : Manual Reservation (MR) creation (SAP standard)
• From R plant / T SL to R plant / K SL
Using one of the following transactions:
• ZKANBAN_SCAN (Upload the Mobile Device)
• PKBC (Scan empty card barcode)
• PK13N (Manual kanban replenish. Request)
• Z_TRANS_FROM_NATCO (Manual Request)

Page 41
Step 3 (Automatic) : Purchase Requisition (Preq) creation
• PReq type NB
• Purchasing group = P99
• On R plant / T SL
• T SL address becomes the address of K SL
Step 4 (Automatic) : Purchase Order (PO) creation by conversion of the Preq (DIP interface)
• PO type ZPO1
• Purchasing group = P99 / purchasing organization = AI99
• On R plant / T SL (address of the K SL)
• Free item
• Output message ZSC1, for IDOC creation
• Job scheduled 5 times per day to reprocess all reservations without Preq & PO.
ZPMST_INTKB_WO_PO_RECOVERY planned to reprocess all reservations without Preq & PO.
• All Errors are logged in the table ZDMSTT_INTKB_LOG
Step 5 (Automatic) : IDOC creation from ARP to Natco (DIP interface)
• custo ALE for the message ORDERS :
• in xEA : / vendor, outbound parameters ORDERS for partners AI99_FNT1, AI99_FNZ1, AI99_FTO1, AI99_FFF1
• in xGI : from partner xEA, inbound parameters ORDERS , with process code ORDE
• Cross-referencing of the material code and BUM.

Step 6 (Automatic) : Sales Order (SO) creation in Natco (DIP interface)
• SO type ZTIK from table ZEDSDC / activity type TT02NF
• SO valuated, against Cost centre and WBS from table ZDPGAT_COST_OBJ (transaction ZDPGAT_COST_OBJ)
• Sold-to = ARP PO vendor
• Ship-to from table ZDMACTSHIPTO / ARP K SL
Step 7 (Automatic) : Outbound Delivery (OD) creation
• OD type ZTKD
(no more OD could be created even
if the delivered quantity is not the requested quantity)
program ZPMSTRLIV_ARP (To group OD and create TO from PO-SO)
Step 8 to 10 : prepare + picking + shipment process + GI on LV
• AS IS process – scanned document is a WM-OL or a WM-LL family (function module : ZFMTRZ01_IDENT_DOC)
• TO printed with ARP kanban information needed for the replenishment (ID, Module, Bin).
• Shipping note printed with information for the transfer (no specific transfer form) quantity.
• WM stock has to be in the right storage type : storage types defined in “Removal Strategy” for the concerned
warehouse number.
• Batch picked must have “production date” and “vendor batch number”. Otherwise, GR can’t be done in PEA.
• Add Job for picking

Page 43
Step 11 : automatic GI on OD type ZTKD
• GI valuated, against Cost centre and WBS from the SO assignment
• The SO is completed even if the delivered quantity is less than the requested quantity
Step 12 (Automatic) : GR IDOC creation from Natco to ARP (DIP interface)
• custo ALE for the message MBGMCR :
• in xGI : for partner xXA, outbound parameters MBGMCR / GR
• in xEA : from partner xXA, inbound parameters MBGMCR / GR , with process code ZGR
• Cross-referencing of the material code, BUM, cost center and WBS (becomes a CO order in ARP)

Page 44
Step 13 (Automatic) : GR creation in ARP
• Movement type I01
• GR valuated, against Cost centre and CO order (cross-ref of GI assignment)
• A new batch is created in ARP, with an internal number, and the vendor batch n° in ARP is copied from the Natco batch
• The serial numbers are the same in both systems
Step 14 (Automatic) : PO closure
• Done in the same time than the GR
• In the PO item, the flag “delivery completed” is flagged even if the received quantity is less than the requested quantity
• New entry filled in the table ZDMSTT_KB_AUTOTR with material document I01, reservation and item.
Step 16 (Automatic) : Inbound process : transaction MIGO on reservation
• Job ZPMWMR_KB_AUTO_TR scheduled to post reservations basing on entries in the table ZDMSTT_KB_AUTOTR. The
aim is to post the quantity received by material document I01 and not the requested quantity at reservation level.

Overview Return Flow KANBAN TIP (1/2)
The materials are refused at Shopfloor or the Kanban control cycle should be removed. Thus the material
should be transferred from Kanban bin (ARP) to the warehouse of the ordering / manufacturing plant
(legacy system). The following steps have to be performed:
 Cancellation of the Kanban consumption of the refused quantity with MIGO, movement type Z62
or 202 (depending on flying / non-flying good); last GI document retrieved via MB51
 cancellation of the GI material document leads to Kanban stock
 Simplified process: No material transfer posting from Kanban storage location to quality stock of
blocked storage location (no quality inspection)
 The material return process to the ordering / manufacturing plant is performed as follows (process
flow chart: see next page):
i. Legacy system: Create Transfer Request (transaction Z_TRANS_FROM_ARP)
ii. ARP system: pick in NK** storage location (transaction VL02N)
iii. ARP system: create shipping document (transaction ZVT04N)
iv. Legacy system: Post the transfer from technical SLOC to main SLOC (transaction MB1B)
In case of materials batch managed in PGI: Post the GR to main stock with regard to PO

Prerequisites Return Flow KANBAN TIP (1/4)
 Prerequisites (see following view):
 ARP material master data (MM01 / MM02):
I. Sales views are created on FR99/99 (with Cash discount = X, Tax data for FR: MWST = 0
and LCFR = A, Item category group = NORM; Transport Grp. + Loading Grp. = Z001)
II. Update MRP view 2: production SLOC = storage location NK** (Kanban SLOC for which
the material return has to be posted)
III. Update MRP view 3: availability check = Z2
 ARP Customer Material Info Record (VD52) created for customer AI99_**** (**** = ordering /
manufacturing plant) on sales area FR99/99 with the following values:
I. Customer material = material code in ARP;
II. plant = ordering / manufacturing plant
 PGI material master data (MM01):
I. Purchasing view is created in ordering / manufacturing plant
If this view isn’t already created (manufactured part): Create with purchasing group P99

ARP Material master data: Sales views
Page 48
ARP transaction MM01 / MM02:
I. Sales views are created on FR99/99 (with Cash discount = X, Tax data for FR: MWST = 0 and LCFR = A,
Item category group = NORM; Transport Grp. + Loading Grp. = Z001)

ARP Material master data: MRP views
Page 49
ARP transaction MM02:
II. Update MRP view 2: production SLOC = storage location NK** (Kanban SLOC for which the material
return has to be posted)
III. Update MRP view 3: availability check = Z2

ARP Customer-Material Info Record
Page 50
ARP transaction VD52:
I. Enter Customer AI99_**** (**** = ordering / manufacturing plant), sales area FR99/99, and material
II. Maintain Customer material = material code in ARP; plant = ordering / manufacturing plant

ARP
Process steps Return Flow KANBAN TIP
Page 51
A-F Legacy system
Manual action
Automatic action
Purchase requisition
& reservation
Purchase order
Transfer Request
Parasitic flow Kanban Intermediate:
Stocks should be transferred from ARP (Kanban storage loc.) to
legacy system (main warehouse)
Z_TRANS_FROM_
ARP
Sales order
Outbound delivery Goods issue on OD Shipment
Goods receipt
Transit storage location
Transfer
From transit storage location
to main storage location
Closes PO
Closes
reservation
1
2
3
4
5 6
9
7
10
8
ZVT04N
MB1B
(311)
VL02N

Process steps Return Flow KANBAN TIP Natco  ARP (1/10)
1st step (ARP): Identify Kanban storage location of Kanban module
Transaction PKMC: Check details of Kanban module (supply area) + replenishment strategy of concerned
material and plant

2nd step (ARP): Identify last material document of the Kanban consumption posting
Transaction MB51: Enter material, plant, storage location, and mvt. type Z61 (in case of KB replenishment
strategy T112) or 201 (in case of KB replenishment strategy T113)
 Example: Material document 4903869355, CO order GSSS45202

3rd step (ARP): Cancel consumption posting of material quantity to be returned
Transaction MIGO, activity “Cancellation” / “material document”
• Enter material document to be cancelled & change posting date to actual date
• Add reason for movement (code 9999 + text)

4th step (ARP): Retrieve PGI material code of the ARP Kanban material
Transaction ZXREF_WEB, XREF rule “MDMATIDPR0”
• Enter material and click on “Search”

5th step (PGI): Create transfer request in PGI system
Transaction Z_TRANS_FROM_ARP
• Don’t change PR type (NB), purchasing organisation, purchasing group (P99)
• Enter supplying plant, receiving plant & receiving storage location
• Enter PGI material code, quantity, delivery date
Result after execution:
PO & reservation created + listed
in the display log

6th step (ARP): Retrieve ARP sales order on basis of PGI purchase order
Transaction VA03, enter “*” + PGI PO no., click on “Search” (alternatively check MD04)

7th step (ARP): Create Outbound Delivery with regard to Sales Order
Transaction VL10I: enter SO no. + delete default values of delivery creation date
Mark SO and click on “create in background”
Result after execution:
OD is created

8th step (ARP): Post Goods Issue of Kanban material with regard to the OD
Transaction VL02N, tab “picking”
• Enter picked quantity (= material return qty) and click on “Post Goods Issue”
Result: GI is posted in ARP; automatic GR with regard to PGI PO is posted
Afterwards: Create Shipment

9th step (ARP + PGI): Check if the material movements have been processed
Transaction MB51, enter material + plant (codes of the ARP/PGI system), and actual date

10th step (PGI): Transfer material quantity from technical SLOC to main stock
Transaction MB1B, transfer posting with regard to reservation no.
• enter reservation no. of step 5 (to be retrieved by MMBE or MB24) and post
Last step (as-is):
perform the put-away into right storage type

type)
S4 Define blocking
indicators
S5 Kanban card is
created
Master Data
Create Kanban Loop
S6 Scan bin empty
S7 Apply a
S8 Monitor
Execute Kanban Loop
Monitor Kanban Loop
Process steps
• Monitor status of Kanban Card: T° PK11
• Control cycle and Kanban evaluation : T° PK18
• Monitor Delayed Replenishments : T° PKAL
• Process Kanban Replenishment error : T°
PK50
• Check Correction : T° PK13N

Monitor Kanban Loop
• There are two levels of monitoring:
1. Monitor the replenishment of Kanban supply area which is covered by a
complete process called the milk run.
The milk run scope is:
• Replenish the cards
• Correct the storage errors
• Scan
• Raise ID cards with anomaly
• Process replenishment with error status
• Manage/prepare the milk run
2. Manage the flow with a periodic monitoring which could lead to a
modification of its sizing (accurate rules) or even to a modification of the
logistic flow (specific rules).
• The monitoring of Kanban replenishment is essential to check if the execution is
running as expected.
Page 64

Execute Kanban Loop
Kanban status sequence
Problem?
Request for
replenishment
YES
NO
Problem solved
Request again
for
replensihment
TO confirmation
• The status "WAIT" is the initial status.
• This status is mandatory to be set on all
Kanban card of a Kanban loop to be
able to remove it.
• Indicates that
there is an issue
during the
replenishment
request.
• Kanban cards get status
“EMPTY” at the TO picking
confirmation in S-W-K,
reception or edition of
Kanban card in S-K. In SAP
standard, it’s mandatory to
deliver the Kanban. It’s not
possible to set the status
“WAIT” from Kanban cards
with the status “EMPTY”. • “EMPTY” status turns to “FULL”
when :
‒at Goods Receipt for external
procured Kanban
‒at Inbound flow from production for
Kanban supplied by Work Order
‒at transfer posting for Kanban
supplied by stock
Click on statuts for
more details
WAIT (initial
status)
FULL
EMPTY
ERROR

Process steps
S1 Monitor status of
Kanban Card
S1' Control cycle and
Kanban evaluation
S1'' Monitor Delayed
Replenishments
S1’’’Manage Kanaban
Replenishment errors

Monitor the Kanban Loop
Monito Kanban TIP
S1 Monitor
status of
Kanban Card
S1' Control
cycle and
Kanban
evaluation
S1'' Monitor
Delayed
Replenishments
S1’’’Manage
Kanaban
Replenishment
errors
N° Outbound
Delivery
OD
item
PO Number Supply Area Planned
Receipt
Plant Sloc Plant Sloc Supplier Material Magasin
fiche
article
Batch
number
OD item
quantity
UQ
1
140489189 10 4200478580
E50-
PMPKR1 15/06/2015 TOF TMTM FTO1 TKAA AI99_FTO1 5167340808 TMTM 11 PCE
2 140785893 10 4200764381
D35LP63KM
1 10/08/2016 TOF T80M FTO1 TKAA AI99_FTO1 7815247454 T80M 24 PCE
3 140792008 10 4200770215
E51LP65KM
3 23/08/2016 TOF TMTM FTO1 TKAA AI99_FTO1 7123002877 TMTM 10 PCE
4 140842731 10 4200478591
E50-
PMPKR1 15/06/2015 TOF TMTM FTO1 TKAA AI99_FTO1 5150602509 0 5 PCE
N° Picking
Status
WM
Status
Goods mvt
status
Batch
stock
Material
stock
Comment Issue Actor
1 A A A 0 0 Picking cannot be done Insuffisant material stock St Eloi
3 C C A 0 30
Impossible to Post the
Good issue
Pour le poste 000010 , 10 numéros de série sont
requis pour l'immo. St Eloi
Kanban TIP monitoring: list of OD errors
OD information
Problem details + Resolution actor

Monitor status of Kanban Card
• This report indicates the number of Kanban cards per status
 Enter via transaction PK11
Enter Plant
Validate or press Enter
2
1
2
1
Select an option
to sort output
Select an option
to narrow output
S1 Monitor
status of
Kanban Card
S1' Control
cycle and
Kanban
evaluation
S1'' Monitor
Delayed
Replenishments
S1’’’Manage
Kanaban
Replenishment
errors

Control cycle and Kanban evaluation
• This report indicates the number of Kanban cards per control cycle
 Enter via transaction PK18 Enter Plant and additional selection fields
Execute
2
1
2
1
S1 Monitor
status of
Kanban Card
S1' Control
cycle and
Kanban
evaluation
S1'' Monitor
Delayed
Replenishments
S1’’’Manage
Kanaban
Replenishment
errors

Monitor Delayed Replenishments
• This report indicates the delayed Replenishments
 Enter via transaction PKAL Enter Plant and additional selection fields
Execute
2
1
2
1
S1 Monitor
status of
Kanban Card
S1' Control
cycle and
Kanban
evaluation
S1'' Monitor
Delayed
Replenishments
S1’’’Manage
Kanaban
Replenishment
errors

Process Kanban
replenishment error (1/7)
Transaction PK50: User can manage Kanban card in Error status
1. The Kanban correction button : reset the status that cause the issue
Enter selection criteria
Execute
Select a Kanban card
2
1
3
1
2
3
Remarks:
 The milk runner is in charge of the scan with errors as soon as they are
created. A scan error list should be generated by the system when data
are transferred to it.
S1 Monitor
status of
Kanban Card
S1' Control
cycle and
Kanban
evaluation
S1'' Monitor
Delayed
Replenishments
S1’’’Manage
Kanaban
Replenishment
errors

From the Kanban processing window user can access to card information by
selecting the follow buttons :
Process Kanban
S1 Monitor
status of
Kanban Card
S1' Control
cycle and
Kanban
evaluation
S1'' Monitor
Delayed
Replenishments
S1’’’Manage
Kanaban
Replenishment
errors

Using Kanban correction button, the system launch PK31 transaction to remove the
error Kanban status. Select the Kanban correction
button
Double click on the Error status
Correct the reason of the error
Click on the Kanban corr.
Button
Check the change of status
2
1
3
1
2
3
4
4
5
5
Remark:
 Transaction PK31 can be launched from Transaction PK13N > right
click on the card to treat > select « error correction »> Transaction PK31
is then launched
Process Kanban
S1 Monitor
status of
Kanban Card
S1' Control
cycle and
Kanban
evaluation
S1'' Monitor
Delayed
Replenishments
S1’’’Manage
Kanaban
Replenishment
errors

User can check correction in PK13N transaction
Before correction
After correction
Process Kanban
S1 Monitor
status of
Kanban Card
S1' Control
cycle and
Kanban
evaluation
S1'' Monitor
Delayed
Replenishments
S1’’’Manage
Kanaban
Replenishment
errors

Transaction PK50: User can manage Kanban card in Error status
2. The Reverse button : Abort the request and set back the status “Full”
1
2
Enter selection criteria
Execute
Select a Kanban card
2
1
3
3
Process Kanban
S1 Monitor
status of
Kanban Card
S1' Control
cycle and
Kanban
evaluation
S1'' Monitor
Delayed
Replenishments
S1’’’Manage
Kanaban
Replenishment
errors

1
Select the Kanban correction
button
Double click on the Error status
Click on the Reverse
Check the change of status
2
1
3
4
2
3
4
Remark:
 Transaction PK31 can be launched from Transaction PK13N > right
click on the card to treat > select « error correction »> Transaction PK31
is then launched
Process Kanban
S1 Monitor
status of
Kanban Card
S1' Control
cycle and
Kanban
evaluation
S1'' Monitor
Delayed
Replenishments
S1’’’Manage
Kanaban
Replenishment
errors

User can check correction in PK13N transaction
Before correction
After correction
Process Kanban
S1 Monitor
status of
Kanban Card
S1' Control
cycle and
Kanban
evaluation
S1'' Monitor
Delayed
Replenishments
S1’’’Manage
Kanaban
Replenishment
errors

KANBAN INTERMEDIATE PHASE V0.pptx

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