Kanban Replenishment: Empty Container Signals a Refill from the Main Store (311)
Pull instead of plan: a control cycle keeps a fixed number of containers at the line's supply area. When a container runs empty its status is set to EMPTY, which triggers a stock transfer from the main store; setting it FULL again posts the transfer (311). MRP is not involved.
Educational content. SAP behaviour varies by configuration and release. Spotted something off? Report it.
Digital twin
01A control cycle defines the loop
Control cycle CC-000123: 3 containers of 20 EA at PSA-ASSY-01, refilled from SLoc 0001.
Business scenario
Assembly line 1 keeps 3 containers of 20 EA RM-1000 at production supply area PSA-ASSY-01 (SLoc 0002). The main store (SLoc 0001) refills each container when the line empties it.
All companies, numbers and documents are fictional demo data.
Step-by-step flow
- 01
A control cycle defines the loop open in twin
Control cycle CC-000123: 3 containers of 20 EA at PSA-ASSY-01, refilled from SLoc 0001.
It replaces planning with a fixed loop: the line can never hold more than three containers.
- 02
The line empties container 1 open in twin
The line uses 20 EA. Consumption is backflushed by the line's confirmations (261): PSA 60 → 40.
Consumption is posted separately, typically by backflush.
- 03
Container 1 is empty open in twin
The operator puts the empty container on the return shelf. What triggers the refill?
Replenishment is triggered by actual use, at the moment it happens.
- 04
Kanban does not wait for MRP open in twin
MRP may still plan the material's total requirement, but it does not trigger Kanban refills — the empty container does.
That is what makes Kanban fast and simple on the shop floor.
- 05
Status EMPTY creates the transfer open in twin
Scanning the card sets container 1 to EMPTY. A stock transfer reservation for 20 EA from SLoc 0001 is created.
Other strategies would create a production order, a PO or a run schedule quantity instead.
- 06
Refilled container returns — status FULL (311) open in twin
The store fills the container and brings it back. Setting it to FULL posts 311: SLoc 0001 −20, SLoc 0002 +20.
One scan both closes the loop and books the stock where it physically is.
- 07
Loop closed open in twin
PSA back to 60 EA in 3 full containers. No planner touched it.
Kanban suits steady, high-volume parts; MRP stays in charge of overall quantities.
SAP documents
Stock impact
| Step | Plant / SLoc | Stock type | MvT | Change |
|---|---|---|---|---|
| The line empties container 1 | 1000 / 0002 | Unrestricted use | 261 | −20 EA |
| Refilled container returns — status FULL (311) | 1000 / 0001 | Unrestricted use | 311 | −20 EA |
| Refilled container returns — status FULL (311) | 1000 / 0002 | Unrestricted use | 311 | +20 EA |
Accounting impact
Components consumed by production (backflush)
TypicalThe line empties container 1
- Dr Consumption — production orders (GBB/VBR)₹20,000
- Cr Inventory — raw materials (BSX)₹20,000
Consumption is posted by production confirmations, not by the Kanban status change.
Typical conceptual flow. Actual G/L accounts and posting behaviour depend on material valuation, automatic account determination and system configuration.
Movement type
- 311Transfer posting SLoc to SLoc (Kanban refill)Reversal: 312
- 261GI for order (backflush)Reversal: 262
Keeps line-side supply topped up by a simple pull signal from the shop floor, without planning each replenishment.
Transactions & Fiori apps
- PKMC — Maintain Control Cycles
- PK13N — Kanban Board (supply area view)
- PK21 — Kanban Status Change (manual)
- MIGO — Goods Movements
- Kanban apps (control cycles, board)Names and availability depend on release and scope
Differences by SAP version
Classic Kanban: PKMC, PK13N, PK21.
Same transactions plus Fiori apps; EWM-managed supply areas are possible.
Kanban scope item with Fiori apps.
Configuration
Replenishment strategies
Configuration dependentIn-house production, external procurement or stock transfer — each creates a different replenishment element.
Goods receipt at status FULL
Configuration dependentWhether setting FULL posts the movement automatically.
Prerequisites
- Production supply area assigned to a storage location
- Control cycle with replenishment strategy
- Material flagged as Kanban-relevant (excluded from or included in MRP as configured)
Master data
- Production supply area (PSA)
- Line-side location assigned to a storage location.
- Control cycle
- Containers, quantity and strategy.
Organizational structure
- Plant 1000
- SLoc 0001 (store) and 0002 (supply area)
Tables
| Table | Description |
|---|---|
| PKHD | Control cycles |
| PKPS | Kanban containers and status |
Integration
- MMStock transfer (311) or procurement elements, depending on the strategy.
Common errors
“Setting EMPTY creates nothing”
Likely causes: Replenishment strategy incomplete; Control cycle not released
Where to look: PKMC · Kanban board error log
Troubleshooting
Something went wrong? Work through these checks in order. They are diagnostic questions, not configuration instructions — confirm changes with your system owner.
CHECK 1
No replenishment
- Is the strategy complete?
- Is the source storage location stocked?
Interview questions
How does Kanban work in SAP PP?
A control cycle defines a material, a production supply area, number of containers and quantity per container, and a replenishment strategy. When a container is empty its status is set to EMPTY (scan, board or automatically), which creates the replenishment element — a transfer reservation, production order, PO or run schedule. Setting it to FULL posts the goods receipt or transfer.
Does Kanban post consumption?
No. Consumption is posted separately — typically by backflush in production. Kanban controls replenishment.
Quiz
References
Explanations are original. They summarize standard behaviour; always validate against your system's release and configuration.
Version history
| Version | Change |
|---|---|
| 1.0.0 | Initial version. |