Kanbans with limited turns

What do we mean by Kanbans with limited turns?

In KanbanBOX, when we talk about kanbans with limited turns we refer to a quantity limit sets for a specific kanban loop, that affects the number of maximum replenishments released to the supplier.

For example, for a kanban loop with kanban quantity of 100 pieces and a quantity limit set at 1000 pieces, maximum number of kanbans released to the supplier is 10. When you reach the limit, KanbanBOX blocks all the following kanban releases, holding kanbans in Empty status.

Quantity limit is used to:

• Manage open orders with the supplier, by limiting kanban card turns until the complete consumption of the total order quantity.
• Components with a part number change or a technical drawing review, to run out the remaining stock at supplier before sending a new kanban order for the new part number or technical drawing.
• Manage kanban orders for a particular contract order, to control the kanban replenishments till the completion of the contract order.

What does a kanban loop with quantity limit look like?

Once the quantity limit is set, in the kanban board you can see the limit details by clicking on the kanban loop header:

• Remaining quantity before reaching the limit.
• Number of remaining releases.

Before reaching the limit, KanbanBOX sends an alert by coloring the loop header and by sending an email to the loop Manager.

A yellow mark colors the header to notify the user that kanban quantity limit is almost reached. Clicking the header, you can always see the remaining quantity and the remaining releases.

When the limit is reached, KanbanBOX sends a second alert to the loop Manager and the kanban loop is blocked. A red mark colors the header to highlight that the loop has reached the limit. After reaching the limit, KanbanBOX blocks all released cards of the loop and sets them as "Empty", with no possibility to set a forward status.

Set a quantity limit

Procedure:

1. Go to Kanban boards, search or filter the specific kanban loop.
2. Click on the header of the kanban loop and then on Manage limit.
3. In the new page, click on Edit limit and then select Yes next to Set kanban loop limit.
4. Fill in these fields:
   • New quantity limit: this is the quantity limit. When reached, the customer cannot release any other kanban cards to the supplier. The number of pieces can match the quantity of the contract order with the supplier, the residual stock in the warehouse or a quantity for a specific order in contract.
   • Send a warning when the remaining is less than or equal to: when this quantity is reached, KanbanBOX sends a warning to the loop manager and highlights the loop header as yellow.
   • Considered kanbans: to consider only the kanban cards or also the extra cards in the limit.
5. Click on Submit.

Update a quantity limit

Procedure:

1. Go to Kanban boards, search or filter the kanban loop.
2. Click on the kanban loop header and then on Manage limit.
3. In the new page, click on Edit limit and then select Yes next to Set kanban loop limit.
4. Update:
   • New quantity limit.
   • Send a warning when the remaining is less than or equal to.
   • Considered kanbans
5. Click on Submit.

Delete a quantity limit

Procedure:

1. Go to Kanban boards, search or filter the kanban loop.
2. Click on the kanban loop header and then on Manage limit.
3. In the new page, click on Edit limit and then select No next to Set kanban loop limit.
4. Click on Submit.