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80310A: LEAN Manufacturing in Microsoft Dynamics AX 2012

Module 1: Concepts and Overview
This module provides the conceptual foundation for an appropriate understanding of the basic concepts in Lean manufacturing, including the structure of the Lean functionality, and the required setup in Microsoft Dynamics AX 2012.
Lessons

  • Core Concepts
  • The Value Stream
  • Introduction to Production Flows
  • Introduction to Kanbans
  • Simple Production Flow
  • High Level Production Flow
  • Setup and Interconnectivity


After completing this module, students will be able to:

  • Explain Lean basic concepts.
  • Explain the Value Stream theory.
  • Describe the production flow concept and how it is used in Microsoft Dynamics AX 2012.
  • Explain the Kanban concept and how it is used in Microsoft Dynamics AX 2012.
  • Describe the Simple Production Flow and the High Level Production flow
  • Set up time units.
  • Set up the production flow model and explain the capacity settings.
  • Set up work cells as resource groups.
  • Set up Lean schedule groups.
  • Describe the new inventory breakdown concept for Lean manufacturing in Microsoft Dynamics AX 2012.
  • Describe standard costing and back flush costing and how they are used in Lean manufacturing in Microsoft Dynamics AX 2012.

 

Module 2: Production Flows
This module explains the purpose of production flows, how to set them up, how they are vital as the foundation for the Lean manufacturing in Microsoft Dynamics AX 2012, and the implications that the production flow has from a costing and inventory point of view.
Lessons

  • Production Flow Versions
  • Takt and Cycle Times
  • Activities Setup
  • Single Transfer Activity Production Flow
  • Two Activity Production Flow: Process and Transfer
  • Activity Relations
  • Multiple Activity Scenarios
  • Inventory Integration
  • Semi-Finished
  • Costing Implications

 

Lab : Creating a Single Process Activity Production Flow

  • Create a New Resource Group for the Work Cell Steps
  • Create a New Production Flow and Version Steps 1-8
  • Create a New Production Flow and Version Steps 9-16
  • Create a Process Activity Steps 1-7
  • Create a Process Activity Steps 8-12
  • Activate the Production Flow Version Steps 1-2

Lab : Multiple Activity Production Flow

  • Multiple Activity Production Flow Steps 1-8
  • Multiple Activity Production Flow Steps 9-20
  • Multiple Activity Production Flow Steps 21-26

After completing this module, students will be able to:

  • Create a new production flow version.
  • Set up takt/cycle times.
  • Set up process type activities.
  • Set up single transfer type activities.
  • Set up a two activity production flow containing transfer and process type activities.
  • Define predecessors/successors.
  • Describe activity relations and constraints.
  • Describe picking activities and setup required.
  • Describe semi-finished product and setup required.
  • Describe costing implications.

 

Module 3: Use and Manage Kanbans
This module provides a base level introduction into the various types of Kanbans and an overview of how they are best used in the Lean manufacturing production environment.
Lessons

  • Kanban Types
  • Kanban Replenishment Strategies
  • Subcontracting Activities and Manufacturing Kanbans


After completing this module, students will be able to:

  • Describe manufacturing Kanbans and explain the different ways they can be used to streamline business processes using Microsoft Dynamics AX 2012.
  • Define withdrawal Kanbans and explain how they are used to move materials.
  • Describe fixed quantity Kanbans and how they compare to fixed bin and fixed card Kanban systems.
  • Define event Kanbans and describe how they can be used to trigger pull events.
  • Describe scheduled Kanbans and when they should be used.
  • Describe subcontracting scenarios using Kanbans.

 

Module 4: Fixed Quantity Kanbans
This module explains how to set up and process fixed quantity Kanbans, including rule setup, job planning, using schedule boards, and processing Kanban jobs.
Lessons

  • Kanban Rule Setup
  • Kanban Job Planning
  • Kanban Printing
  • Kanban Processing - Process Jobs
  • Kanban Processing - Transfer Jobs


Lab : Configure a Fixed Quantity Kanban Rule

  • Step by Step: Creating the Kanban Rule for Process Activity
  • Step by Step: Creating the Kanban Rule for the Transfer Activity
  • Step by Step: Creating the Standard Cost for the Item

Lab : Planning a Kanban on the Kanban Board
Lab : Kanban Processing on the Kanban Board for Process Jobs
Lab : Kanban Processing on the Kanban Board for Transfer Jobs

After completing this module, students will be able to:

  • Describe how fixed quantity Kanbans are used in Microsoft Dynamics AX 2012.
  • Define how to set up and configure fixed quantity Kanban rules.
  • Review the planning process for a fixed quantity Kanban.
  • Explain how to use the Kanban schedule board in the planning process for fixed quantity Kanbans.
  • Explain how to use printing pick lists and Kanban cards to signal processes on the shop floor.
  • Describe how to use the Kanban board for process jobs when using fixed quantity Kanbans.
  • Describe the processing of fixed quantity Kanbans.

 

Module 5: Event Kanbans
Since event Kanbans are only created out of related demand, they belong to the production category of “make-to-order" and are created when certain events occur. This module describes these events and how to set up and process event Kanbans.
Lessons

  • Kanban Rule Setup
  • Sales Line Events
  • Capable to Promise
  • Kanban Line Event
  • BOM Line Event
  • Stock Replenishment Event


Lab : Configure an Event Kanban Rule

  • Step by Step: Create and Release New Color
  • Step by Step: Lean Schedule Group
  • Step by Step: Kanban Rule

Lab : Process a Sales Line Event

  • Step by Step: Enter Sales Order
  • Step by Step: Produce Quantity Signaled by Kanban
  • Step by Step: View Sales Order

Lab : Process a Sales Line Event with CTP

  • Step by Step: Setup
  • Step by Step: Kanban Schedule Board
  • Step by Step: Sales Order

Lab : Kanban Line Event

  • Step by Step: Enter Sales Order
  • Step by Step: Plan the Kanbans
  • Step by Step: Produce the Kanbans
  • Step by Step: Transfer the Speaker Set

Lab : Set up a BOM Line Event Kanban Rule

  • Step by Step: BOM
  • Step by Step: Production Flow
  • Step by Step: Kanban Rule

Lab : Process a BOM Line Event

  • Step by Step: Process a BOM Line Event

Lab : Set up a Stock Replenishment Event Kanban Rule

  • Step by Step: Item Coverage Settings
  • Step by Step: Kanban Rule

Lab : Process a Stock Replenishment

  • Step by Step: Enter Sales Order
  • Step by Step: Shop the Sales Order
  • Step by Step: Plan and Prioritize Kanban

 

After completing this module, students will be able to:

  • Describe how event Kanbans are used in Microsoft Dynamics AX 2012.
  • Define how to set up and configure event Kanban rules and the corresponding event types.
  • Describe how to use the Kanban board for process jobs when you use event Kanbans.
  • Describe the processing of event Kanban jobs.
  • Demonstrate how to set up and process a sales line event.
  • Demonstrate how to set up and process a sales line event with Capable to Promise (CTP).
  • Demonstrate how to set up and process a Kanban line event.
  • Demonstrate how to set up and process a BOM line event.
  • Demonstrate how to set up and process a stock replenishment event.

 

Module 6: Scheduled Kanbans
This module explains the setup of a scheduled Kanban rule and describes Master Planning settings that affect these rules. It also describes how to plan scheduled Kanbans, including how to work with planned orders, the Supply Overview form, and the scheduled Kanban Process Boards.
Lessons

  • Planned Orders of Type Kanban
  • Supply Schedule
  • Kanban Rule Setup
  • Planning Scheduled Kanbans


Lab : Scheduled Kanban Rule Setup

  • Step by Step: Create and Release New Color
  • Step by Step: Product Family
  • Step by Step: Lean Schedule Group
  • Step by Step: Default Order Settings
  • Step by Step: Kanban Rule

Lab : Scheduled Kanban

  • Step by Step: Enter Forecast
  • Step by Step: Run Master Planning
  • Step by Step: Review Supply Schedule
  • Step by Step: Plan and Process

After completing this module, students will be able to:

  • Describe the behavior of planned orders of type Kanban.
  • Describe the Supply schedule form and the relationship with scheduled Kanbans.
  • Describe how scheduled Kanbans are used in Microsoft Dynamics AX 2012.
  • Define how to set up and configure scheduled Kanban rules.
  • Describe the planning process for a scheduled Kanban.
  • Describe the planning considerations for scheduled Kanbans.

 

Module 7: Activity Based Subcontracting
This module describes how subcontracting can be set up in a Lean production environment to allow manufacturing activities to be performed by outside vendors.
Lessons

  • Subcontracting Vendor Payments
  • Resource Group/Work Cell
  • Production Flow with Subcontracting Activities
  • Subcontracting as an Alternate Resouce
  • Cost Accounting of Subcontracted Services


Lab : Process a Subcontract Activity

  • Step by Step: Create Kanban Tickets for Withdrawal Kanbans
  • Step by Step: Create Kanban Tickets for Manufacturing Kanbans
  • Step by Step: Replenish the Kanban Transfer Job
  • Step by Step: Plan the Kanban Jobs
  • Step by Step: Start the Kanban Process Jobs
  • Step by Step: Release Purchase Orders
  • Step by Step: Complete the Kanban Process Jobs

Lab : Using an Alternate Subcontractor

  • Step by Step: Create Kanban Tickets for Manufacturing Kanbans
  • Step by Step: Assign and Plan Alternate Kanban Rule

After completing this module, students will be able to:

  • Describe how to set up subcontracting vendor payments.
  • Describe how to configure a resource group/work cell as subcontracted.
  • Describe how activity-based subcontracting is used in Microsoft Dynamics AX 2012.
  • Define how to set up and configure subcontracting activities in production flows.
  • Define how to use alternate process flows with subcontracting activities.
  • Describe how to use the Kanban board for process jobs for subcontracting activities.

 

Module 8: Production Flow Costing
This module explains the costing setup required to work with production flows in Microsoft Dynamics AX 2012. It also describes how the flow of costs that originate from the transactions are used to process the Kanbans within these production flows.
Lessons

  • Backflush Costing
  • Standard Cost Requirement
  • Components for Lean Manufacturing
  • Reporting Production Flow Activities
  • Subcontracting
  • Backflush Costing


Lab : Configure Standard Costing in Microsoft Dynamics AX2012

  • Step by Step: Costing Version Setup
  • Step by Step: Cost Group Setup
  • Step by Step: Set up Shared Categories and Cost Categories
  • Step by Step: Select Resource Group Cost Categories
  • Step by Step: Costing Sheet Setup - Part 1
  • Step by Step: Costing Sheet Setup - Part 2
  • Step by Step: Product Details

Lab : Calculation of Standard Cost Based on a Production Flow
Lab : End a Kanban Process Job and Observe Posted Costs

Lab : Costing for Subcontracted Activity

  • Step by Step: Create Kanbans
  • Step by Step: Transfer and Produce Kanbans
  • Step by Step: Review Subcontracting Costing Before and After Receipt of PO

Lab : Perform Periodic Backflush Costing

After completing this module, students will be able to:

  • Describe the concept of backflush costing and how it is used in Dynamics AX 2012.
  • Describe conversion cost for items produced by a Kanban in a production flow.
  • Describe the different calculation methods of standard costs for items produced with a Kanban job.
  • Understand how costs are reported to the general ledger when producing items using Lean process flows.
  • Demonstrate how to view the costing for a Kanban job based on a subcontracted activity.
  • Describe production flow periodic posting using the backflush costing calculation.

 

Module 9: Kanban Quantity Calculations
This module explains how to setup, use and process Kanban calculations in order to adjust the Kanban rules.
Lessons

  • Kanban Quantity Calculation Policies


Lab : Calculating Kanban Quantities

  • Step by Step: Review Kanban Quantity Calculation Policy
  • Step by Step: Kanban Quantity Calculation

After completing this module, students will be able to:

  • Define how to set up and configure Kanban quantity calculation policies.
  • Describe how to create the Kanban quantity calculation to generate, calculate and update Kanban rules. 

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4 days
$2,200.00

 

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