Using Kanban Workbenches

The following topics describe how you use the two kanban workbenches—Kanban Sizing Workbench and Kanban Process Workbench—to size and evaluate kanban loops, evaluate and modify kanban processes, and perform some card management activities.

Kanban Workbench Overview
Describes the capabilities of the kanban workbenches.

Workbench Elements
Describes the frames and functions of the kanban workbenches.

Workbench Data
Lists and describes the fields available for viewing or updating in the workbenches.

The QAD .NET UI offers two menu options—Kanban Sizing Workbench and Kanban Process Workbench—that let you select, view, and modify kanban sizing and process data in two ways:

• Directly in a grid; this is similar to spreadsheet applications such as Microsoft Excel. Modifiable fields are white; blue fields are read-only.

• In individual data frames, in which fields are grouped logically based on their functions. In many cases, the layout of the frames indicates the relationships between calculated fields and source values. Note that the majority of grid fields display on the tabs. However, a limited number of values display only in the grid.

Important: Although the workbenches display as menu items in the character user interface, they run only in QAD .NET UI.

For the most part, the workbenches display the same data. Major differences are:

• The search criteria. In the Sizing workbench, you can search on several criteria related to kanban loops sourced by processes, external suppliers, or inventory supermarkets. The Process workbench provides search criteria to let you drill down to specific kanban processes.

• The information available in the grid. The Process workbench shows process, process-item, and loop sizing data for each process found by the search criteria. The Sizing workbench is limited to the same loop sizing data.

• The values you can update. For example, you can view process information related to a specific loop in the Sizing workbench for reference. However, since the process typically supports several loops, you must use the Process workbench to modify related values. When a field is modifiable in one workbench but not the other, the read-only version is shaded in gray.

Use the workbenches to evaluate the kanban loops for a specified manufacturing process, inventory source, or external supplier. You can manipulate various factors, including the every-part-every interval (EPEI) for the supplying process and the quantity of kanban containers, and have the system calculate the optimum number of cards based on the EPEI.

If the sizing or process activity needs to be done in more than a single workbench session, you can save you work as a simulation, return to it later, continue to make changes, and then finally commit the updates to the database when you are finished.

When you have finalized the workbench activity, you can update process, supermarket, and kanban loop records with the revised detail, then create and print cards using tools on the Kanban Card Management menu. For loops that have already been sized, the system recommends changes in the number of kanban cards. You can then inactivate, activate, delete, create, or print cards as needed.

You also can reconcile cards from within the workbench. The system compares the current number of active cards to the optimum number and displays the number of out-of-balance loops on the Reconcile/Print Cards button. See Reconcile Cards for information. This feature even lets you print new or reactivated cards from within the workbench.

Note: Unless you use the automatic card reconciliation feature, resizing loops does not automatically inactivate or delete unneeded cards, or create new ones. You must do this manually using tools on the Kanban Card Management menu. See Managing Kanban Cards.

Typically, you use the workbenches as a first-time sizing tool for new kanban loops or adjusting processes. Individual menu programs are available for such activities as recalculating EPEI, updating safety stock, and determining buffer and kanban sizes using historical and projected supermarket performance data. Some programs give you the option of automatically updating loop data with the new calculations. However, you can use the two workbenches at any time to resize loops and adjust processes.

Additionally, when you size kanban loops supplied by a manufacturing process, you can recalculate, analyze, and update the following attributes of the process:

The Analyst Data frame displays a variety of information about the selected process or kanban loops to help the planner make decisions about appropriate loop setup and sizing. See Analyst Data.

• Supermarket demand data either in Kanban Master Maintenance or, optionally, using Average Demand Calculation (17.2.9) and Safety Stock Calculation (17.2.2)