Kanban maintenance

What is Kanban Maintenance?

Over time, the consumption of materials managed by kanban can vary. As a result, it may become necessary to update the sizing of kanban loops by adding or removing cards.

Consumption maintenance

The Consumption maintenance proposes the scaling down of a kanban loop based on the consumption recorded by KanbanBOX in the last period, normally the last 5 Lead Times.

Procedure:

1. Get in Kanbans > Kanban maintenance > Maintenance from consumptions;
2. In the table Kanban loops maintenance from KanbanBOX statistics check the Maintenance alert and check the Adjustment needed and the Suggested adjustment;
3. Resize from the Operations column.

How to read the table fields useful for resizing

The table contains a series of fields that refer to the loop master and specific fields for performing maintenance.

Field	Description
Average Real Lead Time	Represents the average real Lead Time of the loop. The real Lead Time of a kanban card is calculated as the difference between the Full date and the Release date. The analysis period for the average Lead Time calculation corresponds to the analysis period used to calculate the Maximum consumption per day from KanbanBOX.
Comparison between average real LT and current loop LT	Represents the percentage difference between the Average Real Lead Time and the Lead Time of the kanban loop.
Maximum consumption per day from KanbanBOX	Represents the maximum daily consumption calculated with the moving average on Lead Time. The quantity of consumed material is detected when an available card is declared in the state Released, while the default analysis period is the last 5 Lead Times. The analysis period can be changed from Settings > Company Settings > Kanban consumption calculation.
Adjustment needed	It represents the percentage scaling necessary to have a sizing perfectly aligned with the detected consumptions.
Suggested adjustment	It represents the number of cards that are suggested to be added or removed from the kanban loop to get closer to the correct sizing (the resizing may slightly differ from the necessary resizing since the increases/decreases are made of discrete units).
Maintenance alert	Visual alert useful to filter the loops for which it's suggested to increase/decrease the number of cards. The icon represents the loops for which a change in the number of cards is suggested. Click on the icon to deactivate it (for example, because you do not want to temporarily downsize the loop). The alert will become active again if occurs a further deviation of +/- 20% of the detected consumption or in any case after 30 days.
Change in stock value	It represents the economic impact on the total of the stock in the warehouse if the resizing suggestion is accepted. To view it, you must have completed the Statistical cost parameter in the advanced fields of the part master data.

Operations

The operations you can perform to resize the loop are:

• : each click increases by 1 the number of cards in the loop;
• : with each click, you reduce by 1 the number of cards in the loop;
• : by clicking, the link will be resized according to KanbanBOX suggestions;
• : link to the statistics page (see the guide Kanban loop statistics);
• : to access the page Edit your kanban loop.

Maintenance import

To carry out a massive adjustment of the loops due to changes in the parts' consumption already provided (for example for a product with seasonality), it's possible to import external data.

To do it, it's mandatory to enter the partner identification code in the partner database (field Partner number, see the guide Create and update a partner).

Procedure:

1. Log in Kanbans > Kanban maintenance > Import consumptions;
2. Click on the link kanban_maintenance_import_cons.xls to automatically download the Excel file. Once downloaded, open the file and enter the consumption to be imported. Follow the instructions on how to compile the file shown in the Help sheet (it is not mandatory to keep the name kanban_maintenance_import_cons.xls);
3. Save the file and upload it by clicking on Choose file in the field Excel file for consumption data, then click on Import consumption data;
4. Resize.

Log in Kanban loops maintenance from imported consumption from Kanbans > Kanban maintenance > Maintenance from import.

The table contains a series of fields that refer to the kanban master and specific fields for performing maintenance.

Field	Description
Maximum consumption per day from KanbanBOX	Represents the maximum daily consumption calculated with the moving average on Lead Time. The quantity of consumed material is detected when an available card is declared in the state Released, while the default analysis period is the last 5 Lead Times. The analysis period can be changed from Settings > Company Settings > Kanban consumption calculation.
Maximum consumption per day from import	It is the imported data.
Adjustment needed	It represents the percentage scaling necessary for aligning the sizing to the imported consumption.
Suggested adjustment	It represents the number of cards that are suggested to be added or removed from the kanban loop to get closer to the correct sizing (the resizing may slightly differ from the necessary resizing since the increases/decreases are made of discrete units).

Operations

The operations you can perform to resize the loop are:

• : each click increases by 1 the number of cards in the loop;
• : with each click, you reduce by 1 the number of cards in the loop;
• : by clicking, the link will be resized according to KanbanBOX suggestions;
• : link to the statistics page (see the guide Kanban loop statistics);
• : to access the page Edit your kanban loop.

Resizing actions

The Operations possible are:

• : each click increases by 1 the number of cards within the loop. A kanban card in the state New in created in the board;
• : with each click, you reduce by 1 the number of cards inside the loop. The number of cards on the board doesn't decrease immediately, but only after the release of a card in the state Full;
• : by clicking, the link is resized according to KanbanBOX suggestions.