The calculation of the replenishment events is based on the determination of reorder events. For this, the logic is as follows:
- Whenever a box is consumed and the current fill level of the channel is above the minimum fill level, no reorder event is created.
- Whenever a box is consumed and the current fill level of the channel is equal to the minimum fill level, a reorder event is created for the amount boxes needed to fully fill the channel.
- Whenever a box is consumed and the current fill level of the channel is below the minimum fill level, a reorder event is created for one box.
A material channel has a channel length of 4 and the minimum level of the channel is 2. This means, material will be reordered for the first time when the channel has only 2 boxes left. In this case, two boxes are reordered through the E-Kanban system. If the channel still has three boxes, no reorder is triggered through the system. Once the material channel only carries one box, the channel fill level is below the minimum level, then only one additional box is reordered through the system. Hence, in the two cases described above, two timers are started. The first one (minimum level of 2 boxes reached) will be stopped once the two ordered boxes arrive at the channel. The second timer will be stopped after later ordered box is added to the channel.