Kanban & Lean Replenishment

Business Central's native planning is push-based: the planning worksheet and MRP/MPS engine generate supply from forecasts and reorder policies. That works for procurement, but it floods the production floor with material nobody is consuming yet. Kanban & Lean Replenishment flips the signal — line-side stock refills only when the floor actually pulls it.

ECOSIRE builds this as a per-tenant AL extension installed directly on your Business Central environment (Online or on-prem). It is not an instant AppSource download — we develop it against your item master, locations and bin structure, deploy it as a signed extension, and support it after go-live.

What it does

The extension introduces a Kanban loop master record linking a stocked item to a supplying location (supermarket or supplier) and a consuming line-side bin. Each loop owns a number of electronic Kanban cards sized by your demand and lead time. When consumption is posted — via item journal, consumption journal, or a point-of-use scan — an event subscriber detects the bin drop below its trigger and raises a replenishment signal: a transfer order, purchase order, or production order depending on the loop's replenishment source.

Two-bin and supermarket stocking are modelled natively with table and page extensions on Location and Bin, plus a new Kanban Loop, Kanban Card, and Kanban Signal table set. A Kanban sizing calculator computes card count and quantity from average consumption, replenishment lead time and a safety factor, so loops stay right-sized as demand shifts.

Signals are driven by a job queue entry for time-based sweeps and by real-time event subscribers for consumption postings. Everything is exposed through the BC OData/REST API and custom API pages so MES, scanners, or Power Platform flows can read loop status and confirm card returns.

Honest scope: this is a focused lean-execution layer. It complements — not replaces — BC manufacturing and planning.