Forecast module to bring together pull logic and forecasting
The KanbanBOX tool that helps you manage future needs without compromising the pull logic of kanban
Kanban is based on pull logic: producing only what is needed, when it is needed. But this does not mean that future forecasts should be underestimated by principle. In fact, many companies already have forecast data calculated by their ERP system, and not using them when they can support material planning would be a waste of valuable information.
So how can forecasts be combined with the pull logic of KanbanBOX? The answer is simple: the Forecast module. This module integrates forecast data with the historical consumption recorded in the platform, offering a more complete view and even more effective management of the electronic kanban system.
However, it is important not to misunderstand the purpose of the module: the forecast data imported into the module do not automatically determine the number of cards in a kanban loop (otherwise it would be a push tool). Its purpose is to provide useful information that supports more informed decision-making. In this way, the Forecast module helps the company and its suppliers prepare more efficiently and maintain a solid and effective pull-based system.
Let’s explore the features of the Forecast module in more detail.
Sharing forecast data
Why sharing forecast data with suppliers matters
Sharing forecast data with suppliers is not just a good operational practice: it is a key element in building a strong relationship and a more reliable supply service. When partners have early visibility into potential demand trends, they can plan production more effectively, avoid emergencies, reduce delays, and ensure more consistent service levels. This transparency strengthens mutual trust and improves the quality of flow along the entire supply chain. Not surprisingly, suppliers often request this information: having updated forecasts allows them to organize their operations more efficiently and support the customer company in a more proactive and stable way.
Manual sharing of forecast data
Without KanbanBOX, many companies with forecast data find themselves sharing it with suppliers through time-consuming and unstructured manual processes.
Typically, this requires exporting a report from the ERP, converting it into an Excel file, filtering and reformatting it for each supplier who needs to receive it, and then sending it via email. All of this must be repeated for 10, 15, 20 or more suppliers according to a defined schedule.
Furthermore, there is a risk that each supplier may receive different versions of their file, not synchronized or potentially containing errors. This creates confusion and makes it more difficult to ensure that everyone is working with the same updated information.
KanbanBOX Forecast module eliminates all of this.
Sharing forecast data with the KanbanBOX Forecast module
The first feature of the Forecast module is to allow companies to easily share forecast data with suppliers.
The company only needs to import the file into KanbanBOX (either manually or automatically): the software will route the data to the correct suppliers, enabling each of them to view in their dedicated section only the information relevant to them.
A significant time and energy saver for whoever manages this process, with the added assurance that each supplier can independently access accurate and up-to-date information.
Confirmed production capacity based on forecast data
The Forecast module does more than simply distribute forecasts to suppliers: within the same interface, it provides a field called “Confirmed quantities,” which suppliers can use to indicate if they are unable to meet the forecasted volumes, specifying the quantities they can guarantee.
This allows the customer company to detect potential issues early, take action in advance and benefit from clearer, more structured communication. This feature promotes stronger and more reliable collaboration, reduces the risk of surprises, and contributes to a more stable and responsive supply flow.
Optimal loop sizing
The optimal sizing of kanban is the number of cards needed to avoid both excess inventory and stockouts, ensuring a material flow consistent with the company’s production and/or commercial needs.
KanbanBOX automatically calculates suggestions for the optimal loop size based on actual consumption recorded within the reference Lead Time.
[We discussed this in our article dedicated to kanban maintenance]
With the Forecast module, the data used to perform proper loop sizing becomes more complete. The dedicated section displays two sizing suggestions:
- The first is the one mentioned above, based on actual consumption recorded by KanbanBOX
- The second is based on forecasted consumption imported from the ERP.
Both calculations use the same algorithm; what changes is simply the data set. In the first case, the calculation is based on historical consumption data, while in the second it relies on forecasted consumption.
The manager can evaluate both suggestions, compare them and make a more informed decision, either accepting one of the suggested values or choosing a different one.
It is important to highlight that the final choice regarding the number of cards always remains in the hands of the manager, as only someone who thoroughly understands internal processes, company constraints and specific demand patterns can determine the most appropriate sizing for each loop.
Importing forecast data into KanbanBOX: manual and automatic options
To import the files containing forecast data generated by the ERP, the company can choose between two options:
- Manual: the user downloads the forecast file from the ERP and imports it into KanbanBOX in just a few clicks. To update the data, the user simply needs to upload the updated file whenever desired, synchronizing the two systems in seconds.
- Automatic: the user does not need to perform any manual action. This option is available only after setting up a dedicated integration between KanbanBOX and the ERP system (not included with the Forecast module). In this case, any forecast changes generated by the ERP are automatically transmitted and imported into KanbanBOX, keeping both the supplier-visible data and the loop sizing calculations constantly updated.
How to activate the Forecast module
Activating the Forecast module is quick and fully autonomous: simply log into your KanbanBOX license, go to Import > Forecast and enable the feature in just a few clicks. If you want to integrate the Forecast module with your ERP system, please contact your KanbanBOX referent.
As indicated on the activation page, the Forecast module is available as a 30-day free trial. You can deactivate it at any time from Settings. At the end of the trial period, billing will start automatically.
If the module is deactivated during the free trial, access will be immediately suspended.
Start now your free trial! With the Forecast module, you can easily integrate your ERP forecasts with the historical data recorded by KanbanBOX.