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COURSE: 80310 LEAN MANUFACTURING IN MICROSOFT DYNAMICS ® AX Last Revision: August 2011 This courseware is provided “as-is”. Information and views expressed in this courseware, including URL and other Internet Web site references, may change without notice. Unless otherwise noted, the examples depicted herein are provided for illustration only and are fictitious. No real association or connection is intended or should be inferred. This courseware does not provide you with any legal rights to a
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    COURSE: 80310 LEAN MANUFACTURING IN MICROSOFT DYNAMICS  ®   AX   Last Revision: August 2011 This courseware is provided “as-is”. Information and views expressed in this courseware, including URL and other  Internet Web site references, may change without notice. Unless otherwise noted, the examples depicted herein are provided for illustration only and are fictitious. No real association or connection is intended or should be inferred. This courseware does not provide you with any legal rights to any intellectual property in any Microsoft product. Complying with all applicable copyright laws is the responsibility of the user. Without limiting the rights under copyright, no part of this courseware may be reproduced, stored in or introduced into a retrieval system, or transmitted in any form or by any means or for any purpose, without the express written permission of Microsoft Corporation. Copyright © 2011 Microsoft Corporation. All rights reserved.  Microsoft  ®  ,    Microsoft     Dynamics ®  , Microsoft  ®   PowerPoint  ®  ,    Microsoft  ®   SQL Server  ®   data management software and Microsoft Dynamics ®  AX are trademarks of the Microsoft group of companies. All other trademarks are  property of their respective owners. This course content is designed for Microsoft Dynamics ®  AX 2012.    Table of Contents i Introduction 0-1   Welcome ...........................................................................................................0-1   Microsoft Dynamics Courseware Contents ........................................................0-2   Documentation Conventions .............................................................................0-3   Student Objectives ............................................................................................0-4   Chapter 1: Lean Manufacturing Concepts and Overview 1-1   Objectives .........................................................................................................1-1   Introduction .......................................................................................................1-1   Core Concepts ..................................................................................................1-2   The Value Stream ........................................................................................... 1-12   Introduction to Production Flows ..................................................................... 1-14   Introduction to Kanbans .................................................................................. 1-16   Simple Production Flow .................................................................................. 1-22   High Level Production Flow ............................................................................ 1-24   Setup and Interconnectivity ............................................................................. 1-28   Summary ........................................................................................................ 1-38   Test Your Knowledge ...................................................................................... 1-39   Quick Interaction: Lessons Learned ................................................................ 1-41   Solutions ......................................................................................................... 1-42   Chapter 2: Production Flows 2-1   Objectives .........................................................................................................2-1   Introduction .......................................................................................................2-1   Production Flow Versions .................................................................................2-3   Takt and Cycle Times .......................................................................................2-4   Activities Setup .................................................................................................2-9   Lab 2.1 - Creating a Single Process Activity Production Flow ......................... 2-14   Single Transfer Activity Production Flow ......................................................... 2-20   Two Activity Production Flow: Process and Transfer ....................................... 2-22   Activity Relations............................................................................................. 2-23   Lab 2.2 - Multiple Activity Production Flow ...................................................... 2-26   Multiple Activity Scenarios .............................................................................. 2-29   Inventory Integration ....................................................................................... 2-34   Semi-Finished ................................................................................................. 2-41   Costing Implications ........................................................................................ 2-51   Summary ........................................................................................................ 2-53   Test Your Knowledge ...................................................................................... 2-54   Quick Interaction: Lessons Learned ................................................................ 2-56   Solutions ......................................................................................................... 2-57   Chapter 3: Use and Manage Kanbans 3-1   Objectives .........................................................................................................3-1   Introduction .......................................................................................................3-1   Kanban Types ...................................................................................................3-2   Kanban Replenishment Strategies ....................................................................3-5   Subcontracting Activities and Manufacturing Kanbans .................................... 3-22   Summary ........................................................................................................ 3-26   Quick Interaction: Lessons Learned ................................................................ 3-29    Lean Manufacturing in Microsoft Dynamics  ®   AX 2012 ii Solutions ......................................................................................................... 3-30   Chapter 4: Fixed Quantity Kanbans 4-1   Objectives .........................................................................................................4-1   Introduction .......................................................................................................4-1   Kanban Rule Setup ...........................................................................................4-2   Lab 4.1 - Configure a Fixed Quantity Kanban Rule ......................................... 4-26   Kanban Job Planning ...................................................................................... 4-29   Lab 4.2 - Planning a Kanban on the Kanban Board ........................................ 4-39   Kanban Printing .............................................................................................. 4-40   Kanban Processing - Process Jobs ................................................................ 4-42   Lab 4.3 - Kanban Processing on the Kanban Board for Process Jobs ............ 4-54   Kanban Processing - Transfer Jobs ................................................................ 4-55   Lab 4.4 - Kanban Processing on the Kanban Board for Transfer Jobs ............ 4-58   Summary ........................................................................................................ 4-59   Test Your Knowledge ...................................................................................... 4-60   Quick Interaction: Lessons Learned ................................................................ 4-63   Solutions ......................................................................................................... 4-64   Chapter 5: Event Kanbans 5-1   Objectives .........................................................................................................5-1   Introduction .......................................................................................................5-1   Kanban Rule Setup ...........................................................................................5-2   Lab 5.1: Configure an Event Kanban Rule ...................................................... 5-17   Sales Line Events ........................................................................................... 5-20   Lab 5.2 - Process a Sales Line Event ............................................................. 5-26   Capable to Promise ........................................................................................ 5-28   Lab 5.3 - Process a Sales Line Event with CTP .............................................. 5-31   Kanban Line Event .......................................................................................... 5-34   Lab 5.4 - Kanban Line Event ........................................................................... 5-38   BOM Line Event .............................................................................................. 5-41   Lab 5.5 - Set up a BOM Line Event Kanban Rule ........................................... 5-43   Lab 5.6 - Process a BOM Line Event .............................................................. 5-45   Stock Replenishment Event ............................................................................ 5-46   Lab 5.7 - Set up a Stock Replenishment Event Kanban Rule .......................... 5-50   Lab 5.8 - Process a Stock Replenishment Event ............................................ 5-52   Summary ........................................................................................................ 5-54   Test Your Knowledge ...................................................................................... 5-55   Quick Interaction: Lessons Learned ................................................................ 5-58   Solutions ......................................................................................................... 5-59   Chapter 6: Scheduled Kanbans 6-1   Objectives .........................................................................................................6-1   Introduction .......................................................................................................6-1   Planned Orders of Type Kanban .......................................................................6-2   Supply Schedule ...............................................................................................6-3   Kanban Rule Setup ...........................................................................................6-8   Lab 6.1 - Scheduled Kanban Rule Setup ........................................................ 6-24   Planning Scheduled Kanbans ......................................................................... 6-28   Lab 6.2 - Scheduled Kanban ........................................................................... 6-31  
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