1 Pfep Introduction 2012

PFEP – Plan for Every Part
Introduction
Marek Piatkowski – April 2012
Marek.Piatkowski@rogers.com
1
Introduction - Marek Piatkowski
 Professional Background
 Toyota Motor Manufacturing Canada (TMMC) - Cambridge,
Ontario from 1987-1994
 TPS/Lean Transformation Consulting - since 1994
 Professional Affiliations
 TWI Network – John Shook, Founder
 Lean Enterprise Institute (LEI) – Jim Womack
 Lean Enterprise Academy (LEA) – Daniel Jones
 LEI Poland – Tomasz Koch, President
 Lean Transformation Solutions, Toronto, Canada
www.TWI-Network.com
2
What is Plan for Every Part (PFEP) ?
PN-150 Part Supl. Supplier Press Wheel Part's 1=Line #1 Used on # Parts / Kanban System
Part Type Hand Description Model
Number Type Name Line Base Weight 2=Both Oper. # Frame Routing
FU-31301* Bracket RH Front End Sheet Metal Ext Ridgeview 1.12 2 220 1 PN-150 Supplier
FU-31302* Bracket LH Front End Sheet Metal Ext Ridgeview 1.12 2 220 1 PN-150 Supplier
FU-31304-220 Bracket #1 Body Bracket Ext Acemco 4x2 1.4 2 220 2 PN-150 Supplier
FU-31307 Bracket RH Lower Control Arm Ext Tecumseh 4x4 3.1 1 245 1 PN-150 Supplier
FU-31308 Bracket LH Lower Control Arm Ext Tecumseh 4x4 3.1 1 245 1 PN-150 Supplier
FU-31313* Bracket RH Front Shock Ext Metal Form N. 4x4 2.9 1 255 1 PN-150 Supplier
FU-31314* Bracket LH Front Shock Ext Metal Form N. 4x4 2.9 1 255 1 PN-150 Supplier
FU-31319-10* Bracket RH Front Upper Control Arm Ext Ridgeview 4x4 1.3 1 245 2 PN-150 Supplier
FU-31320* Bracket LH Rear Upper Control Arm Ext Ridgeview 4x4 1.1 1 245 2 PN-150 Supplier
FU-31323-10 Bracket RH Front Jounce Bracket Ext Tecumseh 4x4 2.3 1 280 1 PN-150 Supplier
FU-31324-10 Bracket LH Front Jounce Bracket Ext Tecumseh 4x4 2.3 1 280 1 PN-150 Supplier
FU-31569* Bracket RH Engine Differential Ext Hamlin 4x4 2.2 1 255 1 PN-150 Supplier
FU-31570* Bracket LH Engine Ext Hamlin 4x4 2.2 1 255 1 PN-150 Supplier
PFEP is a data base created to gather and maintain information about

FU-31595 Bracket RH T-Bar Sub-assembly Ext Tecumseh 4x4 0.8 1 20 1 PN-150 Supplier
FU-31596 Bracket LH T-Bar Sub-assembly Ext Tecumseh 4x4 0.8 1 20 1 PN-150 Supplier
FU-31599
FU-31600
FU-31601
FU-31602
FU-31603
Reinforcement RH
Reinforcement LH
Bracket
Bracket
Bracket
RH
LH
# 1 Cross Bar
# 1 Cross Bar
Lower Control Arm
Lower Control Arm
Cab Mounting Rear
Ext Luitink
Ext Luitink
Ext Tecumseh
Ext Tecumseh
Ext Tower-Upper
4x4
4x4
4x2
4x2
SW & LW
0.9
0.9
4.2
4.2
1.9
1
1
2
2
2
50
50
240
240
220
1
1
1
1
2
PN-150 Supplier
PN-150 Supplier
PN-150 Supplier
PN-150 Supplier
PN-150 Supplier

all parts, components, supplies, WIP inventories, raw materials,
FU-31604 Bracket Cab Mounting Rear Ext Tower-Upper SC 1.9 2 220 2 PN-150 Supplier
FU-31605 Bracket Upper Control Arm Ext Luitink 4x2 2 2 240 4 PN-150 Supplier
FU-31607 Reinforcement RH Lower Control Arm Bracket 4x2 2 1
FU-31608 Reinforcement LH Lower Control Arm Bracket Ext Tecumseh 4x2 1.5 2 285 1 PN-150 Supplier
FU-31609 Bracket RH Front Jounce Bracket Ext Ridgeview 4x2 0.88 2 250 1 PN-150 Supplier
FU-31610 Bracket LH Front JNC Ext Ridgeview 4x2 0.88 2 250 1 PN-150 Supplier
FU-31639 Bracket RH Tire Stop Ext Ridgeview 0.4 2 30 1 PN-150 Supplier
finished goods and any other form of material used in your processes
FU-31640 Bracket LH Tire Stop Ext Ridgeview 0.4 2 30 1 PN-150 Supplier
FU-31641 Reinforcement RH Center Side Bar Ext Ridgeview SWB 1.3 2 Sub 1 PN-150 Supplier
FU-31642 Reinforcement LH Center Side Bar Ext Ridgeview SWB 1.3 2 Sub 1 PN-150 Supplier
FU-31648 Reinforcement Center Side Bar Ext Ridgeview SC 0.2 2 255 1 PN-150 Supplier
 PFEP data base must have sorting capabilities.

(Most common Excel and Access)
 It also can reside on your current ERP or MRP system
 This data base must be user friendly and accessible to read and ability
to print anywhere in your facility
3
Plan for Establish a position of an Inventory Analyst
Every Part
 Responsible for the PFEP
Step 1  The only person that can modify PFEP system
 Must be notified of any and all changes that are made to any part
 Needs to maintain the PFEP on a common drive so that anyone
throughout the company can view the information
 If this position cannot be created assign this responsibility to an
individual in your Production Control department
 Inventory Analyst must drive Inventory Policy
 Creates less inventory! ( purchased and finished goods)
 Produce what you need when you need it!
4
Plan for Inventory Analyst
Every Part
Key Points - Responsibilities Reasons
Step 1 1. Maintenance and control of max/min 1. To maintain and to keep all information
levels, lead times, order quantities, re- in the system up to date and to provide
order points, etc… in SAP/MRP system feedback to management
2. Maintenance of BOM and Pick Lists 2. Update information at least monthly
3. Management of new and obsolete parts 3. Add new parts and remove obsolete
and components once from the system
4. Plan-for-Every-Part (PFEP) 4. Single source of information
5. Introduction and maintenance of a 5. Kanban cars get lost and Kanban cards
Kanban cards and system must be updated on regularr basis
6. Inventory policies (levels, controls and 6. To review inventory information at
management) monthly Sales and Operations meetings
5
Plan for Identify the Type of Parts in your PFEP Data Base
Every Part
 Purchased Parts  Finished Goods
Step 2
6
Plan for Start collecting Information for (PFEP)
Every Part
 For every part, gather information related to:
Step 3  Part identification – part #, description, unique features …
 Storage information – container type, pieces/container …
 Transportation - what equipment needed to move parts
 Delivery – how frequently do we ship and deliver
 Production capabilities – daily or hourly production rates
 Customer Requirements – forecast and actual shipments
 Group every part into one of the three categories:
 Runners (A), Repeaters (B), or Strangers (C)
7
Plan for Establishing PFEP – How much detail?
Every Part
 Part number  Container type
Step 3 Length
 Description 
 Daily usage  Width

 Point of use location  Height
 Storage location  Weight
 Order frequency  Standard pack quantity

 Delivery frequency
 Supplier name
 Carrier
 Supplier city
 Transit time
 Supplier country
 …
 …
8
Plan for PFEP – Information about the Part
Every Part
 Purchased Parts  Finished Goods
Step 4 1 2 3 4 5 1 2 3 4 5
Information about the Part Information about the Part

Supplier Part Part Model / Customer Part Model /
 Part number Part Number
Number Description
Part Name
Color Part Number
Part Number Description
Part Name
Color
 Customer Part 1722775 1722775 Valve FLAT VALVE LH FU-31301* 1722775 Bracket Lower Control Arm Gray
Number 17107869 17107869 Clip SILVER CLIPS RH FU-31302* 17107869 Bracket Lower Control Arm Blue
 Part Description 17109503 17109503 Spring CPC SPRINGS LH FU-31304-220 17109503 Reinforcement Front Shock Gray
 Part Name 17124075 17124075 Assembly SRHVL Assy RH FU-31307 17124075 Reinforcement Front Shock Black
 Model/Color 24100005 24100005 Body SRHVL BODY LH FU-31308 24100005 Bracket Front Upper Control Blue
25123518 25123518 Plunger SRHVL Plunger RH FU-31313* 25123518 Bracket Rear Upper Control Gray
25175971 25175971 Spring SPRINGS LH FU-31314* 25175971 Bracket Front Bracket Gray
25176235 25176235 Valve FLAT VALVE RH FU-31319-10* 25176235 Bracket Front Bracket Black
25176235 25176235 Clip SILVER CLIPS LH FU-31320* 25176235 Bracket Engine Differential Blue
25176235 25176235 Clip GOLD CLIPS RH FU-31323-10 25176235 Engine Engine Gray
25176236 25176236 Spring SAT. SPRING LH FU-31324-10 25176236 Bracket Upper Control Arm Gray
9
Plan for PFEP – Information about the Container
Every Part
 Purchased Parts and/or Finished Goods
Step 5 7 8 9 10 11 12 13 14 15 16 17
Information about the Packaging Container

Standard Empty Part Full Container
Unit of Quantity per Container Container Container
Container Type Container Type Container Container Weight in Container Length in
 Measure Container Instructions Width in Cm Height in Cm
Quantity Weight in KG KG Weight in KG Cm
 Standard Container Cradboard Box YES Pieces 50 Scrap 0.50 1.728 86.90 120 100 121
Quantity Returnable
Tote YES Lbs 120 Container
1.20 1.608 194.16 120 100 121
 Unit of Measure Returnable
Cart YES Pieces 400 Container
18.00 1.652 678.80 120 100 121
 Quantity per
GOW YES Pieces 25 Scrap 1.60 1.624 42.20 120 100 121
Container
Gon NO Pieces 12 Scrap 22.40 1.484 40.21 100 66 141.5
 Container
Instructions Spool YES Meters 500 Scrap 10.00 350.00 100 66 141.5
Returnable
 Container Tote YES Lbs 300 Container
1.2 1.444 434.40 100 66 141.5
Dimensions and Cradboard Box YES Pieces 50 Scrap 0.50 2.934 147.20 120 60 121
weight
Gon NO Pieces 100 Scrap 22.40 3.082 330.60 120 100 121
Returnable
Cart YES Pieces 100 Container
18.00 2.262 244.20 100 66 141.5
Returnable
Tote YES Lbs 200 Container
1.2 2.778 556.80 138 128 143
10
Plan for PFEP – Shipping Information
Every Part
 Purchased Parts and/or Finished Goods
Step 6 19 20 21 22 23 24 25
Shipping Information
Delivery Min Number of
Order Transportation Shipment Inspection
Order Frequency Lead Time - Shipment Pieces per Min
 Frequency Carrier Frequency Required?
Days Size Shipment
 Lead Times Daily 1 Bradley Express Weekly Box 50 NO
 Carrier 2 / Week 7 FedEx 2 / Week Pallet 2,880 NO
 Shipment Frequency Daily 1 Bradley Express Weekly Box 400 NO
 Min Shipment Size Daily 1 Bradley Express Weekly Box 25 NO
 Number of pieces 1 / Week 3 UPS Weekly Pallet 480 NO

per Shipment When
Needed
10 FedEx Weekly Spool 500 YES
 Is Inspection
Daily 1 Bradley Express Weekly Box 300 NO
Required ?
Daily 1 Bradley Express Weekly Box 50 NO
2 / Week 5 UPS 2 / Week Pallet 2,000 NO
2 / Week 5 UPS 2 / Week Pallet 2,000 NO
Daily 1 Bradley Express Daily Box 200 NO
11
Plan for Developing the PFEP Plan
Every Part
Once you populate the data base you can start planning
Step 7  Develop delivery plans or production plans based on standard
Container sizes
 Identify inventory re-order points and quantities
 Identify re-order frequencies
 Implement standardized parts and components delivery methods
 Identify inventory levels required at each machine and work station
 Identify inventory levels at each storage location and Supermarket
 Define and minimize Standard Pack Quantities
12
Plan for Size of Containers
Every Part
Identify if each container is “Line Ready” – YES or NO
Step 7  Small box, easy to lift
 Less than 12 KG (30 lbs)
13
Plan for
Every Part
Step 7
 Does the part need
repacking?
 Or the container is
Line Ready?
14
Plan for
Every Part
Step 7
 Should we start
talking to our
Supplier about
delivering parts in
Line Ready
containers?
15
Plan for
Every Part
Step 7
 Why do we
spending so much
money on packaging
by Suppliers when
we do not use it and
do not need it?
16
Plan for A B C – Analysis of all Current Parts
Every Part
 Are all current parts in the Data Base active?
Step 8
 When was the last time some of these parts were used?
 Which ones are obsolete or not-active?
Number of Codes Number of Codes Number of Codes

used in last 4 Months
Number of Active – 20%
Codes – 35%
Number of Number of Codes NOT
Not-Active Codes – 65% used in last 4 Months
– 80%
17
Plan for PFEP - Keys to Success
Every Part
 Controlled maintenance of a single database
Step 10  Established system to provide data for updates
 Use database that has sorting capabilities
 Load data in smallest element possible (container size should be three
different entries-length, width and height)
18
Lean Transformation Solutions
This presentation is an intellectual property of F.S.P. Consulting Inc.
No parts of this presentation can be copied or reproduced
without a written permission from:
Marek Piatkowski
F.S.P. Consulting Inc.
iPhone: 416-235-2631
Cell: 248-207-0416
www.TWI-Network.com
19

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PFEP – Plan for Every Part

Marek Piatkowski – April 2012

 Lean Transformation Solutions, Toronto, Canada

PFEP is a data base created to gather and maintain information about

 PFEP data base must have sorting capabilities.

 Daily usage  Width

 Order frequency  Standard pack quantity

Information about the Part Information about the Part

Information about the Packaging Container

 Carrier 2 / Week 7 FedEx 2 / Week Pallet 2,880 NO

 Shipment Frequency Daily 1 Bradley Express Weekly Box 400 NO

 Min Shipment Size Daily 1 Bradley Express Weekly Box 25 NO

 Number of pieces 1 / Week 3 UPS Weekly Pallet 480 NO

2 / Week 5 UPS 2 / Week Pallet 2,000 NO

2 / Week 5 UPS 2 / Week Pallet 2,000 NO

Daily 1 Bradley Express Daily Box 200 NO

Number of Codes Number of Codes Number of Codes

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