Control or Flexibility? Work Orders, Repetitive, and Kanban Side, by Side, by Side

1. Control or Flexibility?Work Orders, Repetitive, and KanbanSide, by Side, by Side John C. Smith, Cascade Engineering Rea Buchanan, QAD Dave Doyle, QAD

2. Agenda • First Hour • Set Up differences • Scheduling and visibility in MPS/MRP • Break 3:30 – 4:00 • Second Hour • Floor Reporting • When to use

3. [P] lanned Order [F] irm Order [R] eleased Order Current Routing Current Routing Frozen Routing Current P/S Current P/S Frozen P/S Fixed due date & qty. Detail inventory allocation Variable due date & qty. No inventory allocation Fixed due date & qty. No inventory allocation Other Options: [E] xploded Order [A] llocated Order Frozen Routing Frozen Routing Frozen P/S Frozen P/S Fixed due date & qty. No inventory allocation Fixed due date & qty. General inventory allocation Overview of Work Order Status

4. Standard P F  E  A  R  C F Final assembly E  A  R  C R Rework A  R  C E Expense R  C C Schedule Cumulative S W Flow Other Uses of Work Orders

5. [P] lanned Order Current Routing Current P/S Variable due date & qty. No inventory allocation [E] xploded Order Frozen Routing Frozen P/S Fixed due date & qty. No inventory allocation Repetitive Status Create Repetitive Schedule?

6. Kanban Status • No order of any type • Each kanban ID (card) has a status: • Empty Accumulate (not authorized) • Empty Authorized • Full • Acknowledged • Shipped • In FIFO • Each kanban ID (card) has an active code: • Active, Inactive, Close, • Cycles, Period

7. Work Order * Repetitive * Kanban Set up Components Product Structure Routing Alternate Structure Alternate Routing Substitute Material Product Structure Routing Alternate Structure Alternate Routing Substitute Material Part Run Sequence Repetitive Lines Line Rate, Allocation% Line Shift times Change Over Rates Items/Steps Processes Supermarkets Kanban Loops Cycle & Set-up Time Average Demand Replenishment Time Kanban Quantity Size Kanban Loops

8. KANBAN Item Maintenance

9. Process Maintenance

10. Process Maintenance Detail

11. Supermarket Maintenance

12. KANBAN Loop Data

13. KANBAN Loop Data

14. KANBAN Workbench

15. KANBAN Workbench

18. Work Order * Repetitive * Kanban Master Scheduling Activity * Review Action Messages * Planned Work Order Approval * No Tasks Required (optional) * Level Mix Schedule * Review Action Messages * Planned Repetitive Schedule Approve

19. Level Mix Workbench

20. Workbench – Mix Analysis

21. Level Mix Workbench – Leveled Schedule

22. Work Order * Repetitive * Kanban MRP Visibility * No Tasks Required * MRP Will Plan New Orders, No Action Needed * Released Work Order Is Scheduled Receipt * Generate New MRP Planned Orders * Repetitive Schedule Shows as Scheduled * Exploded shows as Planned Receipt * Generate New MRP Planned Orders

23. Work Order * Repetitive * Kanban Inter-Plant (DRP) DRP Buy/Sell EMT Requires Level in Product Structure DRP for planning Setup Kanban Loops Between Sites Requires Level in Product Structure DRP Buy/Sell EMT Requires Level in Product Structure

24. Work Order * Repetitive * Kanban Module Scheduling Activity * Work Order Maintenance * Work Order Release * Repetitive Schedule * Line Schedule Workbench * Schedule Update Or Re-Run MRP * Monitor Kanban Workbench for Resizing Move from Status Firm To Allocated, Exploded, Released Move from Status Planned To Exploded Perform Kanban Transactions

25. Take a Break Resume at 4:00

26. Agenda • First Hour • Set Up differences • Scheduling and visibility in MPS/MRP • Second Hour • Floor Reporting • When to use

27. Work Order * Repetitive * Kanban 1. Maintain Work Order 1. RepetitiveSchedule • Kanban Empty • Transaction • Kanban Empty • Accumulating 2. Release WorkOrder • Status Planned • To Exploded

28. Kanban Consume (Empty)

29. Work Order * Repetitive * Kanban 1. Maintain Work Order 1. RepetitiveSchedule • Kanban Empty • Transaction • Run MRP or • Explode Schedule 2. Release WorkOrder • Kanban Empty • Accumulating 3. Work CenterDispatch Report • Kanban • Authorized 3. Work CenterDispatch Report

30. Work Order * Repetitive * Kanban 1. Maintain Work Order 1. RepetitiveSchedule • Kanban Empty • Transaction 2. Release WorkOrder 2. ExplodeSchedule • Kanban Empty • Accumulating 3. Work CenterDispatch Report 3. Work CenterDispatch Report 3. Kanban Authorized 4. Work OrderComponent Issue 4. Dispatch List Pull Components to line 4. Repetitive PicklistTransfer

32. Work Order * Repetitive * Kanban 1. Maintain Work Order 1. RepetitiveSchedule • Kanban Empty • Transaction 2. Release WorkOrder 2. ExplodeSchedule • Kanban Empty • Accumulating 3. Work CenterDispatch Report 3. Work CenterDispatch Report 3. Kanban Authorized 4. Work OrderComponent Issue 4. Repetitive PicklistTransfer 4. Dispatch List Components to line 5. Report Labor by Work Order Operation Employee Quantity Run-Time 5. Kanban Fill/Receive 5. Report Production Employee, Site Item Number Operation Production Line Quantity Produced Run-Time (option)

33. Kanban Fill

34. Work Order * Repetitive * Kanban • 1. Repetitive Schedule • 2. Explode Schedule • 3. Work Center • Dispatch Report • 4. Repetitive PicklistTransfer • 5. Report Labor • 1. Kanban Empty • 2. Kanban Accumulate • 3. Kanban Authorized • 4. Dispatch List • Pull Components • to Line • 5. Kanban Fill/Receive • Maintain Work Order • Release Work • Order • Work Center • Dispatch Report • Work Order • Component Issue • 5. Report Labor 6. Scrap 6. Scrap 6. Scrap • Backflush • Scrap • Work Order Receipt • Receipt/Backflush 7. Not Required

35. Work Order * Repetitive * Kanban • 1. Repetitive Schedule • 2. Explode Schedule • 3. Work Center • Dispatch Report • 4. Repetitive PicklistTransfer • 5. Report Labor • 6. Scrap / Reject • 7. Backflush • Backflush/Receipt • Scrap, Reject, Labor 1. Kanban Empty 2. Kanban Accumulate 3. Kanban Authorized 4. Dispatch List Pull Components to Line 5. Kanban Fill/Receive 6. Scrap 7. Not required • Maintain Work Order • Release Work • Order • Work Center • Dispatch Report • Work Order • Component Issue • Report Labor • Scrap • Work Order receipt • Receipt/Backflush 8. Close WorkOrder 8. Timing Options 8. Not Required

36. Work Order * Repetitive * Kanban 1. Repetitive Schedule 2. Explode Schedule 3. Work Center Dispatch Report 4. Repetitive PicklistTransfer 5. Report Labor 6. Scrap 7. Backflush Receipt 8. Not Required 1. Kanban Empty 2. Kanban Accumulate 3. Kanban Authorized 4. Dispatch List Pull Components to Line 5. Kanban Fill/Receive 6. Scrap 7. Not required 8. Not Required • Maintain Work Order • Release Work • Order • Work Center • Dispatch Report • Work Order • Component Issue • Report Labor • Scrap • Work Order receipt • Receipt/Backflush • 8. Close Work Order 9. Work OrderAccounting Close 9. Not Required 9. Cumulative OrderAccounting Close

37. Work Order * Repetitive * Kanban WIP Balances No WIP Balances Steps May Be Used to Pull Between Operations QTY Order Qty WIP Run Complete Qty Reject Qty Rework Beginning Qty Processed Reworked Rejected Moved Out Scraped Adjusted Current

38. Work Order * Repetitive * Kanban Component Issue * Automatic Backflush with Fill/Receive Or * No Inventory Impact * Work Order Component Issue (Lot/Serial recording) * Substitute * Backflush * Receipt/backflush • * Backflush • * Modify Backflush • Substitute • Lot/Serial Entry • Modify Qty • * Scrap (Non Milestone)

39. Work Order * Repetitive * Kanban Floor Reporting * Must be Released * Not to Exceed Scheduled Quantity * Report in Operation Sequence * Fill * Empty * Ship * Acknowledge • Any Time • * Any Operation • Milestone • * Any Quantity

40. Work Order * Repetitive * Kanban Alternates * Alternate Structure At Release * Alternate Routing At Release * Modify Structure And/or W/O Routing * Must be a defined Kanban Loop * Alternate Structure At Schedule or start * Alternate Routing At Schedule or Start

41. Work Order * Repetitive * Kanban Reports * Operation Detail By transaction * Analysis reports Scrap, Rework, Reject, WIP Adjust *Downtime, Utilization, Efficiency, Cost * Valuation reports WIP, Scrap, Adjust * Operation Detail By transaction * Downtime * Utilization * Efficiency * Status * Cost * History * Dispatch List * Kanban Card Status * Kanban Card Audit * Missing Kanbans * Transaction Audit * Inventory Validation * Historical Buffer Evaluation

42. Work Order * Repetitive * Kanban Other Types of Transactions Rework Non-Productive Downtime Expense Work Order Rework Work Order Non-Productive Downtime Kanban Card Print Limited Use Kanban Kanban Deactivate, Close, Activate Average Demand Calculation Safety Stock Calculation

43. Work Order * Repetitive * Kanban Other Applications, Modules, and Functions WIP Lot Trace Item Run Sequence Cost By Operation Sub-Contract Ops Quality Test by Op WIP Lot Trace Co-Products Configured Orders Sub-Contract Ops Quality Test by Op Attach Project Code Routable Limited Lot Trace Kanban Visualization

44. 10 20 30 WIP Lot Tracing • Issue lot traced components • Assign WIP lot • WIP lot used • Issue lot traced components • WIP Lot moved • (Supports splitting & combining lots) • Move WIP lot into inventory • Assign finished lot number

45. Work Order * Repetitive * Kanban Other Applications, Modules, and Functions WIP Lot Trace Item Run Sequence Cost By Operation Sub-Contract Ops Quality Test by Op WIP Lot Trace Co-Products Configured Orders Sub-Contract Ops Quality Test by Op Attach Project Code Routable Limited Lot Trace Kanban Visualization

46. Supply Visualization - KANBAN Board Graphic representation of a Kanban board

47. ‪ Empty KANBANs Order Point Safety Stock  Shipped KANBANs Acknowledged Kanban  Filled KANBANs Accumulate

48. What Works Best for Me?