Shop-Trak Setting Up the Item Profile for Kanban Replenishment

Kanban replenishment is a feature of Shop-Trak that allows shop floor employees to create replenishment orders based on an Item Profile.  Use the Shop-Trak Item Profile form to set up a profile for each item that can be replenished by employees on the shop floor.

To set up an Item Profile:

1. Open the Shop-Trak Item Profile form.
2. Specify this information:

• Item - This is a required field.  Select the item from the Item list.  The corresponding description displays in the Item Description field.
• Location - This is a required field.  Select the location from the Location list.  The corresponding warehouse displays in the adjacent field.
• Inventory Source - Displays where the item originated, either Purchased, Manufactured, or Transferred.

NOTE:  Item, Location, and Inventory Source make up the index for the record.  Once a record is saved, these fields cannot be changed.  The only way to add another location for an item is to add another item and warehouse for the other location.  If you no longer want the item/location/warehouse record you can delete it.

• Max Open - Specify the maximum number of released orders (purchase, job, and transfer orders) that can be maintained within Infor SyteLine.  Once this limit is reached, no further replenishments can be generated from the shop floor until the orders are processed.  If the limit has been met and another replenishment order is generated, a message displays.  For example:  "The maximum number of Purchase Orders are already open."
• Replenishment Method - This is a required field.  Specify the replenishment method:
• Fixed - Allows the user to define the desired bin quantity.
• MRP - Uses system plans to determine bin quantity.  You can view the plans on the Planning Detail form.
• SyteLean - Uses system plans to determine bin quantity.  SyteLean will adjust plan quantities created through MRP, taking into account history and forecasts.
• If the method is MRP or SyteLean, Shop-Trak looks at the records on the Planning Detail form when replenishing an item.  
1. If there are only future PLN records for the item:
• The order is created for the first PLN.  
• The order receives the date and quantity from the PLN.
• The PLN record is deleted and the order record takes its place on the Planning Detail form.
2. If there are PLN records with a date of today or prior to today:
• An order is created.   
• The order receives the date from the oldest PLN.
• The order quantity is the sum of all PLN records with dates of today and prior to today.  In addition, the quantity will include the quantity from any PLNs looking out the days supply from today.  
• The PLN records are deleted and one order record takes its place on the Planning Detail form.
3. Dates on a Job created by a Shop-Trak Replenishment:
• The job date is today.
• The job end date is the date on the oldest PLN.
• The job start date is calculated using backwards scheduling from the job end date.
4. Planning Parameters

Planning Parameters that affect what is seen on the Planning Detail form include:

• Transfers online.
• CO and Forecast online.
• Mfg and PO online.

If these parameters are checked, orders are added on the Planning Detail form when needed.  For example, you will see a CO record added to the Planning Detail form, but a PLN record for the CO will not be added until MRP runs again.  Therefore, if there is no other PLN for an item, Shop-Trak will not replenish, as it won’t see a PLN.  MRP will run at the scheduled time, or it can be run manually if required.

• Order Type - This is a required field.  Select the type of order to be created during Kanban replenishment (Purchase Order, Job Order, Transfer Order, PO Requisition, or Production Schedule).  Based on the Order Type selected, additional fields display. If new orders are desired for each Kanban replenishment, then the Order field (just below the Order Type field) should be left blank.  For Purchase Orders, where the Order Number is left blank, the PO will be a Regular type. Order types:
• Purchase Order - Created in Planned status.  Vendor will be the rank one vendor/item cross reference if available.  If there is none, lead time will come from the item maintenance.
• Regular Purchase Order Number - New line added as long as the Purchase Order is in Planned status.
• Blanket Purchase Order Number - New release added as long as Purchase Order is in Planned status.
• Prefix may be used on the Purchase Order.  If a Prefix is entered, a new Purchase Order is created using the Prefix and the next sequential  number.  For example:  Prefix of "ab" wil create PO ab0001, ab0002, etc.
• Job Order - Created with routing/BOM copied, status will be set to Released so that it is immediately visible on the Shop-Trak Shop Floor Visual Dispatch.
• Job Order - Optional.  If entered, a new suffix will be added to the job number specified.
• Alternate Routing - If you want to use the routing of another item, enter an item number.  Leaving this field empty will create the job with the current routing of the item.
• Transfer Order - Created in Planned status.  New line added as long as Transfer Order is in Planned status.  Specify these additional fields:  To Site, To Warehouse, From Site, From Warehouse.
• PO Requisition - Created in Planned status. Select a PO Requisition Number.  A new line is added as long as a PO Requisition is in Planned status.
• Production Schedule - New Production Schedule ID and Production Schedule Item will be created with routing/BOM copied in Released status.
• Production Schedule ID - New Production Schedule Release will be created and released.
• Bin Qty - Number of units required per replenishment.  Available with Fixed method only.
• Replenishment Qty - Threshold for order creation.  This field can be left blank, resulting in a new order for each Kanban replenishment processed.
• Accumulated Qty - Displays the sum of quantities for each Kanban replenishment processed.  Once this equals the Replenishment Qty, an order will be created and the field will display any remaining quantity to be processed yet.
• Email and CC - Specify the e-mail address of the person that should receive an e-mail notification that a replenishment has been generated for this item.  

3. Save the data and close the form.

Related Topics

Shop-Trak Kanban Replenishment Log