Kanban and Lean Manufacturing Configuration in SyteLine
SyteLine supports kanban-based pull replenishment alongside traditional MRP push planning, enabling lean manufacturing practices within the ERP system. Kanban in SyteLine operates through the Kanban Card form and integrates with inventory management to trigger production or purchasing based on consumption signals rather than forecast-driven planned orders. Correct kanban sizing and card management prevent both overproduction and stockouts.
Kanban Card Configuration in SyteLine
SyteLine kanban cards are configured per item, per location, and per supply type (production or purchasing). Each card represents a fixed quantity of material and cycles between empty (signaling replenishment) and full (available for consumption). The number of cards and quantity per card determine the total inventory investment in the kanban loop.
- Kanban Card form (SL_Kanban) defining item, location, quantity per card, and number of active cards
- Supply type: production kanban triggering shop orders, purchasing kanban triggering purchase orders
- Card status tracking: Full (inventory available), Empty (replenishment triggered), In Transit (order placed)
- Kanban card quantity calculated as: (Daily Demand x Lead Time x Safety Factor) / Number of Cards
- Barcode-enabled kanban card scanning for shop floor operators to signal empty cards at point of use
Kanban Sizing and Supermarket Design
Kanban sizing in SyteLine must balance responsiveness against inventory investment. The classic kanban formula considers average daily demand, replenishment lead time, and a safety factor for variability. SyteLine supermarket locations serve as controlled buffer points between production stages where kanban quantities are staged and consumed.
- Number of kanbans formula: N = (D x L x (1 + S)) / Q where D=demand, L=lead time, S=safety, Q=container qty
- Supermarket warehouse locations configured in SyteLine for kanban staging and consumption tracking
- Kanban quantity review cycle: monthly for stable items, weekly for new items or volatile demand
- Heijunka (production leveling) patterns influencing kanban replenishment frequency and lot sizes
- Kanban board visualization in SyteLine showing card status by item and work center
Kanban and MRP Integration
SyteLine allows kanban-managed items to coexist with MRP-planned items. The key decision is which items should be kanban-controlled versus MRP-planned. Generally, high-volume, stable-demand components are ideal for kanban while low-volume, variable-demand items remain in MRP. The Kanban flag on the Item record excludes the item from MRP planned order generation.
- Kanban flag on SL_Item excluding the item from MRP gross-to-net planning calculations
- MRP still calculates gross requirements for kanban items to support long-range capacity planning
- Hybrid approach: MRP plans parent assemblies while kanban manages high-volume component replenishment
- ABC/XYZ analysis guiding kanban vs MRP assignment: AX and BX items are kanban candidates
- Transition plan for moving items from MRP to kanban: parallel run period with inventory monitoring
Implement lean manufacturing in SyteLine with properly sized kanban loops -- our lean consultants can guide the setup.
Related Resources
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Infor SyteLineSyteLine Planning Workbench Optimization Guide
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