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Field
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Description
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Item
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Display only. This field displays the identifier for a kanban item.
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Step
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Display only. If a process step is defined for this item in Kanban Master Maintenance, it displays here.
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Source Type
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Display only. This field indicates whether the source of this item, defined in Kanban Master Maintenance, is a supplier, an inventory supermarket, or a manufacturing process.
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Source Site
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Display only. This field displays the site where source process or supermarket is located.
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Source
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Display only. This field displays the source of the item, defined in Kanban Master Maintenance. Depending on the source type, it can be a supplier address code, a supermarket ID, or a kanban process ID.
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Supermarket Site
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Display only. This field displays the site where the kanban supermarket is located.
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Supermarket
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Display only. This field displays the supermarket ID associated with the item in Kanban Master Maintenance.
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Daily Demand (Current and Revised)
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The system displays the current average daily demand for this item. It defaults from the item detail in Kanban Master Maintenance, where it is either entered manually or calculated using Average Demand Calculation. If you modify it in the Revised field and save your changes, the system updates the item detail and sets the Demand Modified field to Yes in Kanban Master Maintenance.
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Daily Demand UM
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Display only. The system displays the item unit of measure specified in Item Master Maintenance.
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Demand Percent (Current and Revised)
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The system displays the current Demand Percent value specified in Kanban Master Maintenance. If an item is supplied to more than one supermarket, this field indicates the percentage of total demand represented by this loop. If you modify it in the Revised field and save your changes, the system updates the Kanban Master Maintenance value.
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Variable Lead Time
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The system displays the variable lead time for kanban items. The value depends on the method used for selecting information in Kanban Workbench.
When you select kanban loops by specifying a source site and process in the Selection Criteria frame, the system calculates variable item lead time as the sum of the setup and cycle times for the order quantity of all other items produced by the process, plus the setup and cycle time for one kanban quantity of the item itself. This total is divided by the number of resources available to the process. When Lead Time Method (Revised) is Variable, the system defaults the calculated value to the Replenishment Time (Revised) field. When Lead Time Method (Revised) is Fixed, Replenishment Time (Revised) defaults from Replenishment Time (Current).
When you select loops by item, supermarket, or site/source rather than by process, the system sets Variable Lead Time to 0 (zero). Replenishment Time (Revised) defaults from Replenishment Time (Current) regardless of the lead time calculation method.
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Internal Hours Per Day
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If Available Time Per Day (Current), which is the available time in Kanban Process Maintenance, in Kanban Sizing Workbench is not zero, Available Time Per Day (Revised) should equal Available Time Per Day (Current).
If Source Type is Process and Available Time Per Day (Current) is zero, Available Time Per Day (Revised) is determined by the following steps:
1. The system searches for a record in Process Calendar Maintenance matching the site and process. If one exists, the defined shift hours will be used.
2. If no record matches the process, the system determines whether a site calendar exists in Site Calendar Maintenance. If it does, the calendar hours will be used.
3. If no matching record is found in Site Calendar Maintenance, the system will use the working hours defined in Domain Calendar Maintenance:
• Available Time Per Day (Revised) = SUM (working hours of this month) / number of working day:
• Internal Hours Per Day = Available Time per day (Revised)
If Source Type is Supplier, Internal Hours Per Day = 24.
If Source Type is Inventory, Internal Hours Per Day is calculated as the Daily time available for 1 week by summing up the total hours scheduled on work days / number of work days in the site calendar. If no site calendar is defined, the system uses the domain calendar.
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External Hours Per Day
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This should always equal 24.
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Replenishment Time (Current and Revised)
Note The “Current” value displays as Replenishment Lead Time on the Order Point Data tab.
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The system displays the total time between recognizing that an item should be reordered and having the item available for use. The current value defaults from the item detail in Kanban Master Maintenance. The default revised value is determined by the Variable Lead Time field. When you save your changes, the system updates the Replenishment Time field in Kanban Master Maintenance based on the revised value.
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Fixed Interval Time
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Display only. This is the amount of time that elapses before the system checks for empty cards for this loop and determines whether the total number of empty cards has reached the order quantity. When Accumulator Type is set to Time in the Card Control Detail Frame of Kanban Master Maintenance, this field displays the value of Accumulator Interval. When Accumulator Type is Schedule, the field is set to the longest time between any two scheduled intervals. When Accumulator Type is Quantity, no Fixed Interval Time is displayed.
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Internal FIFO Time (Current and Revised)
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The system displays the time that the item spends in processes defined as first-in, first-out lanes. The current value defaults from the item detail in Kanban Master Maintenance. If you modify the Revised field and save your changes, the system updates that record.
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External FIFO Time (Current and Revised)
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The system displays the time that the item spends in external FIFO processes such as subcontract operations. The current value defaults from the item detail in Kanban Master Maintenance. If you modify the Revised field and save your changes, the system updates that record.
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Internal Total Lead Time
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Display only. Calculated as:
• Process and inventory loops: Replenishment Time (Revised) + Fixed Interval Time + Internal FIFO Time (Revised)
• Supplier loops: Same as Internal FIFO Time (Revised)
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External Total Lead Time
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External Total Lead Time. Display only. Calculated as:
• Process and inventory loops: Same as External FIFO Time (Revised)
• Supplier loops: Replenishment Time (Revised) + Fixed Interval Time + External FIFO Time (Revised)
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Lead Time (Days)
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Display only. For process loops, calculated as:
Internal Total Lead Time / Internal Hours Per Day + External Total Lead Time / (24 * 60 * 60)
For supplier loops, this is assumed to be 24 hours. For loops supplied by a supermarket, it is based on site calendar data.
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Demand During Lead Time
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Display only. Calculated as:
Daily Demand (Revised) * Lead Time (Days)
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Safety Days (Current and Revised)
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This is the number of days of demand to be used as the basis of determining safety stock for this item. It defaults from the Supermarket Item Detail frame of Kanban Master Maintenance. If you update it, the system recalculates the value of Demand During Safety Time. When you click Save Kanban Data, the system updates the Kanban Master Maintenance record.
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Demand During Safety Time
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Display only. Calculated as:
Daily Demand (Revised) * Safety Days (Revised)
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Safety Stock (Current and Revised)
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This is the quantity of safety stock maintained at the kanban supermarket. It defaults from the Supermarket Item Detail frame of Kanban Master Maintenance. When you change this field and click Save Kanban Data, the system updates the Kanban Master Maintenance record.
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Total Safety Stock Plus Safety Time
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Display only. Calculated as:
Demand During Safety Time + Safety Stock (Revised)
The system updates the loop record in the database with this value when you click Save Kanban Data. Although the value does not display in Kanban Master Maintenance, it is included in the information available to Kanban Visualization.
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Variability Factor (Current and Revised)
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This is a factor that can be applied to the supermarket buffer quantity to account for such things as seasonal demand. It defaults from the Supermarket Item Detail frame of Kanban Master Maintenance. When you change this field and click Save Kanban Data, the system updates the Kanban Master Maintenance record.
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Order Point (Current)
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This is the supermarket inventory level at which a replenishment order is signaled to the supplying process. It defaults from the Supermarket Item Detail frame of Kanban Master Maintenance.
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Order Point (Preliminary)
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Display only. This is the supermarket inventory level at which the supplying process is signaled to replenish the stock.
When the source type is Supplier or Inventory, this is equal to Order Quantity (Current)
When the source type is Process and it is non-pacemaker, this is calculated as:
Daily Demand * EPEI
When the source type is Process, it is a pacemaker, EPEI Auto is Yes, EPEI = 0, and Minimum EPEI = 0, it is also calculated as:
Daily Demand * EPEI
Under all other conditions, the field is set to 0.
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EPE Interval
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Display only. When Type is Process, the system displays the value of EPEI (Revised) from the process data grid. Otherwise, the system sets this field to blank. EPEI calculations are most significant when you are sizing kanbans and supermarkets for all the items in a process.
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Order Quantity (Current)
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This is the number of units the supplying source will produce at any one time. It defaults from the Card Control Detail frame of Kanban Master Maintenance.
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Order Quantity (Preliminary)
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Use of this field depends on the source of the kanban loop:
• For pacemaker processes, the field defaults from Order Quantity (Current) and can be updated.
• For non-pacemaker processes, the field is calculated by the workbench. It cannot be updated.
• For loops with a source type of supplier or inventory, the field defaults to 1 and can be updated.
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Pack Quantity
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Display only. Defaults from the supermarket item detail specified in Kanban Master Maintenance.
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Packs per Kanban (Current and Revised)
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Can be updated. The default value is calculated by dividing the kanban quantity specified in Kanban Master Maintenance by the pack quantity. If you change it, the system updates Kanban Quantity (Revised). When you click Save Kanban Data, the system updates the fields in Kanban Master Maintenance.
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Kanban Quantity (Current and Revised)
Note Kanban Quantity (Revised) displays as Round Up By Kanban Quantity on the Order Point tab.
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Display only. The current value defaults from the Card Tracking Control frame in Kanban Master Maintenance. The revised value is set to:
Pack Quantity * Packs per Kanban (Revised)
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Card Reporting
Note This displays as Adjustment Card Reporting on the Order Point Data tab.
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Can be updated. The field defaults from Kanban Master Maintenance. If you modify it and save your changes, the system updates the loop record. Valid values are:
• Standard. This kanban is reported as empty when the first piece is removed from the container. This has no effect on the order point.
• Add. This kanban is not reported as empty until the last piece is removed from the container. The system increases Order Point (Revised) by the value of Kanban Quantity (Revised).
• Remove. To prevent the number of kanbans required from being overstated by a kanban quantity in loops that should require only one card, the system reduces the Standard calculation by one card.
When this field is Add or Remove, the value of Fractional Kanban can result in a logical inconsistency that causes Order Point (Revised) to equal zero. In this case, the system displays a warning message.
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Fractional Kanban
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Can be updated. The field defaults from Kanban Master Maintenance. If you modify it and save your changes, the system updates the loop record. Valid values cannot be more than 0.99 or less than 0.
This setting lets you control the point at which the system automatically sizes a loop with a second card when it might more logically have only one. The system uses the following logic:
• If Order Quantity (Preliminary) and Order Point (Preliminary) are both greater than zero but less than Kanban Quantity (Revised), and Order Quantity (Preliminary) divided by Kanban Quantity (Revised) is less than or equal to Fractional Kanban, the system sets Order Quantity (Revised) to 0.
• If Order Point (Preliminary) divided by Kanban Quantity (Revised) is greater than Fractional Kanban, the system sets Order Quantity (Revised) to Kanban Quantity (Revised).
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Order Point (Revised)
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Display only. The field initially defaults from the Order Point field in Kanban Master Maintenance. The system updates the value based on sizing calculations. The field is automatically rounded up to an integer multiple of Kanban Quantity (Revised).
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Order Point (Revised) in Kanbans
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Display only. Calculated as:
Order Point (Revised) / Kanban Quantity (Revised)
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Order Quantity Multiple in Kanbans (Current and Revised)
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The system displays the value of Order Quantity Multiple from Kanban Master Maintenance. If you modify the Revised field and save your changes, the system updates that record. When this value is greater than 0, the system increases Order Quantity (Revised) until it is a multiple of this value. Any quantity changes occur after the system makes adjustments based on card reporting and fractional kanban logic.
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Order Quantity (Revised)
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Display only. Calculated as Order Quantity (Preliminary) rounded up to be an integer multiple of Kanban Quantity (Revised). When you save your changes, the system modifies the Card Tracking Control frame in Kanban Master Maintenance. This value can be affected by fractional kanban and card reporting settings.
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Order Quantity (Revised) in Kanbans
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Display only. Calculated as:
Order Quantity (Revised) / Kanban Quantity (Revised)
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Maximum Buffer Size (Current and Revised)
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Display only. Current value defaults from the Buffer Maximum field in Kanban Master Maintenance. Revised value is calculated as:
Order Point (Revised) + Order Quantity (Revised)
When you click Save Kanban Data, the system displays the revised value in the Buffer Maximum field in Kanban Master Maintenance.
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Number of Cards (Current and Revised)
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Display only. Current value defaults from the Number of Cards field in the Card Tracking Control frame of Kanban Master Maintenance. Revised value is calculated as:
Order Point (Revised) in Kanbans + Order Quantity (Revised) in Kanbans
When you click Save Kanban Data, the system displays the new value in the Number of Cards field in the Card Tracking Control frame of Kanban Master Maintenance.
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Number of Cards (Change)
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Display only. Calculated as:
Number of Cards (Current) – Number of Cards (Revised)
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Card Reconciliation
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Can be updated. Defaults from Selection Criteria frame. See Reconcile Cards.
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Run-Out Option
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Can be updated for loops supplied by a process. This field defaults from Kanban Master Maintenance. It is used to indicate that this item is typically made in a quantity large enough to use the entire amount of a specified material regardless of the kanban quantity. Valid values are Yes and No. If you modify this field and save your changes, the system updates the loop record. This field is for reference only; it has no effect on workbench calculations.
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Other Run-Out Data
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Display only. The system displays several reference fields related to material run-out. They default from the Kanban Item Master Maintenance record for the item/step.
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