Course 80310A: LEAN Manufacturing in Microsoft Dynamics® AX 2012

Type:Course
Audience(s):information workers
Technology:Microsoft Dynamics AX
Level:200
This Revision:A
Delivery method:
Instructor-led (classroom)
Length:4 days
Language(s):English, French, German, Italian, Spanish

First published:

22 September 2011
Overview
About this course
This course provides students with a detailed overview of the Lean Manufacturing module in Microsoft Dynamics® AX 2012.  It provides a description of the main features and processes used to run lean manufacturing and includes detailed labs, scenarios, examples, and demonstrations that range from understanding and configuring different types of Kanbans, to subcontracting and setting up production flow costing.
Audience profile
This course is intended for:
  • Partners, consultants, presales consultants, and professionals that have a moderate understanding of basic Lean Manufacturing concepts and production processes.
At course completion
After completing this course, students will be able to:

  • Describe the core concepts of Lean manufacturing.
  • Create a new production flow version and describe activity relations and constraints, picking activities and costing implications.
  • Define Kanbans and describe their types including: withdrawal, fixed quantity, event, scheduled and subcontracting Kanbans.
  • Explain how fixed quantity Kanbans are used including how to set up rules, review planning processes, and use the Kanban schedule board.
  • Describe how event Kanbans are used including how to configure rules, set up sales line events, Kanban line events, BOM line events and stock replenishment events.
  • Describe the processes associated with the planned order type Kanban.
  • Define and setup activity based subcontracting.
  • Describe production flow costing including: back flushing, conversion costs, cost reporting to the general ledger, and how production costing is set up for a Kanban job based on subcontracting activity.
  • Define how to set up and configure Kanban quantity calculation policies and how to create quantity calculations to generate and update Kanban  rules.
Course details
Course OutlineModule 1: Concepts and OverviewThis 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
  • Objectives
  • Introduction
  • Core Concepts
  • The Value Stream
  • Introduction to Production Flows
  • Introduction to Kanbans
  • Simple Production Flow
  • High Level Production Flow
  • Setup and Interconnectivity
  • Summary
  • Test Your Knowledge
  • Quick Interaction: Lessons Learned
  • Solutions
Lab : No Labs in this module.
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 FlowsThis 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
  • Objectives
  • Introduction
  • 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
  • Summary
  • Test Your Knowledge
  • Quick Interaction: Lessons Learned
  • Solutions
Lab : Creating a Single Process Activity Production FlowLab : Multiple Activity Production Flow
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 KanbansThis 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
  • Objectives
  • Introduction
  • Kanban Types
  • Kanban Replenishment Strategies
  • Subcontracting Activities and Manufacturing Kanbans
  • Summary
  • Test Your Knowledge
  • Quick Interaction: Lessons Learned
  • Solutions
Lab : No Labs in this module.
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
  • Objectives
  • Introduction
  • Kanban Rule Setup
  • Kanban Job Planning
  • Kanban Printing
  • Kanban Processing - Process Jobs
  • Kanban Processing - Transfer Jobs
  • Summary
  • Test Your Knowledge
  • Quick Interaction: Lessons Learned
  • Solutions
Lab : Configure a Fixed Quantity Kanban RuleLab : Planning a Kanban on the Kanban BoardLab : Kanban Processing on the Kanban Board for Process JobsLab : 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
  • Objectives
  • Introduction
  • Kanban Rule Setup
  • Sales Line Events
  • Capable to Promise
  • Kanban Line Event
  • BOM Line Event
  • Stock Replenishment Event
  • Summary
  • Test Your Knowledge
  • Quick Interaction: Lessons Learned
  • Solutions
Lab : Configure an Event Kanban RuleLab : Process a Sales Line EventLab : Process a Sales Line Event with CTPLab : Kanban Line EventLab : Set up a BOM Line Event Kanban RuleLab : Process a BOM Line EventLab : Set up a Stock Replenishment Event Kanban RuleLab : Process a Stock Replenishment
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 KanbansThis 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
  • Objectives
  • Introduction
  • Planned Orders of Type Kanban
  • Supply Schedule
  • Kanban Rule Setup
  • Planning Scheduled Kanbans
  • Summary
  • Test Your Knowledge
  • Quick Interaction: Lessons Learned
  • Solutions
Lab : Scheduled Kanban Rule SetupLab : Scheduled Kanban
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 SubcontractingThis module describes how subcontracting can be set up in a Lean production environment to allow manufacturing activities to be performed by outside vendors. Lessons
  • Objectives
  • Introduction
  • Subcontracting Vendor Payments
  • Resource Group/Work Cell
  • Production Flow with Subcontracting Activities
  • Subcontracting as an Alternate Resouce
  • Cost Accounting of Subcontracted Services
  • Summary
  • Test Your Knowledge
  • Quick Interaction: Lessons Learned
  • Solutions
Lab : Process a Subcontract ActivityLab : Using an Alternate Subcontractor
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
  • Objectives
  • Introduction
  • Backflush Costing
  • Standard Cost Requirement
  • Components for Lean Manufacturing
  • Reporting Production Flow Activities
  • Subcontracting
  • Backflush Costing
  • Summary
  • Test Your Knowledge
  • Quick Interaction: Lessons Learned
  • Solutions
Lab : Configure Standard Costing in Microsoft Dynamics AX2012Lab : Calculation of Standard Cost Based on a Production FlowLab : End a Kanban Process Job and Observe Posted CostsLab : Costing for Subcontracted ActivityLab : 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
  • Objectives
  • Introduction
  • Kanban Quantity Calculation Policies
  • Calculating Kanban Quantities
  • Summary
  • Test Your Knowledge
  • Quick Interaction: Lessons Learned
  • Solutions
Lab : Calculating Kanban Quantities
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.
Prerequisites
Before attending this course, students must have:

    • Basic Knowledge of Lean Manufacturing principles and processes.
    • Knowledge of Microsoft Dynamics® AX 2012 Production.
    • Knowledge of Microsoft Dynamics® AX 2012 Trade and Logistics.

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