plan-for-every-part (pfep) - introduction november 2016

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Plan-for-Every-Part (PFEP) Definitions

Thinking win, Win, WIN

PFEP – Plan for Every PartDefinitions

Marek Piatkowski – August 2016


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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 CCM/CAINTRA – Monterrey, Mexico SME, AME, ASQ, CME

Lean Manufacturing Solutions - Toronto, Canada

http://twi-network.com

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What is Plan for Every Part (PFEP) ?

PFEP is a data base created to gather and maintain information about all parts, components, supplies, WIP inventories, raw materials, finished goods and any other form of material used in your processes

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

PN-150 Part Number

Part Type Hand Description Supl. Type

Supplier Name

Press Line

Model Wheel Base

Part's Weight

1=Line #1 2=Both

Used on Oper. #

# Parts / Frame

Kanban System 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

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 Reinforcement RH # 1 Cross Bar Ext Luitink 4x4 0.9 1 50 1 PN-150 Supplier

FU-31600 Reinforcement LH # 1 Cross Bar Ext Luitink 4x4 0.9 1 50 1 PN-150 Supplier

FU-31601 Bracket RH Lower Control Arm Ext Tecumseh 4x2 4.2 2 240 1 PN-150 Supplier

FU-31602 Bracket LH Lower Control Arm Ext Tecumseh 4x2 4.2 2 240 1 PN-150 Supplier

FU-31603 Bracket Cab Mounting Rear Ext Tower-Upper SW & LW 1.9 2 220 2 PN-150 Supplier

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

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

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Establish a position of an Inventory Analyst

Inventory Analyst is responsible for the PFEP data base 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!

Step 1

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ReasonsKey Points - Responsibilities

1.To maintain and to keep all information in the system up to date and to provide feedback to management

2.Update information at least monthly

3.Add new parts and remove obsolete once from the system

4.Single source of information5.Kanban cars get lost and Kanban

cards must be updated on regularr basis

6.To review inventory information at monthly Sales and Operations meetings

1.Maintenance and control of max/min levels, lead times, order quantities, re-order points, etc… in SAP/MRP system

2.Maintenance of BOM and Pick Lists

3.Management of new and obsolete parts and components

4.Plan-for-Every-Part (PFEP)5.Introduction and maintenance of

a Kanban cards and system6.Inventory policies (levels,

controls and management)

Inventory Analyst

Step 1

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Identify the Type of Parts in your PFEP Data Base

Finished Goods Purchased PartsStep 2

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Start collecting Information for (PFEP)

For every part, gather information related to: 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)

Step 3

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Establishing PFEP – How much detail?

Part number Description Daily usage Point of use location Storage location Order frequency Supplier name Supplier city Supplier country …

Container type Length Width Height Weight Standard pack quantity Delivery frequency Carrier Transit time …

Step 3

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PFEP – Information about the Part

Finished Goods Purchased Parts1 2 3 4 5

Part NumberSupplier Part

NumberPart

DescriptionPart Name

Model / Color

1722775 1722775 Valve FLAT VALVE LH

17107869 17107869 Clip SILVER CLIPS RH

17109503 17109503 Spring CPC SPRINGS LH

17124075 17124075 Assembly SRHVL Assy RH

24100005 24100005 Body SRHVL BODY LH

25123518 25123518 Plunger SRHVL Plunger RH

25175971 25175971 Spring SPRINGS LH

25176235 25176235 Valve FLAT VALVE RH

25176235 25176235 Clip SILVER CLIPS LH

25176235 25176235 Clip GOLD CLIPS RH

25176236 25176236 Spring SAT. SPRING LH

Information about the Part1 2 3 4 5

Part NumberCustomer

Part NumberPart

DescriptionPart Name

Model / Color

FU-31301* 1722775 Bracket Lower Control Arm Gray

FU-31302* 17107869 Bracket Lower Control Arm Blue

FU-31304-220 17109503 Reinforcement Front Shock Gray

FU-31307 17124075 Reinforcement Front Shock Black

FU-31308 24100005 Bracket Front Upper Control Blue

FU-31313* 25123518 Bracket Rear Upper Control Gray

FU-31314* 25175971 Bracket Front Bracket Gray

FU-31319-10* 25176235 Bracket Front Bracket Black

FU-31320* 25176235 Bracket Engine Differential Blue

FU-31323-10 25176235 Engine Engine Gray

FU-31324-10 25176236 Bracket Upper Control Arm Gray

Information about the Part

Part number Customer Part

Number Part Description Part Name Model/Color

Step 4

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PFEP – Information about the Container

Purchased Parts and/or Finished Goods

Container Type Standard Container

Quantity Unit of Measure Quantity per

Container Container

Instructions Container

Dimensions and weight

7 8 9 10 11 12 13 14 15 16 17

Container TypeStandard Container Quantity

Unit of Measure

Quantity per Container

Container Instructions

Empty Container

Weight in KG

Part Weight in

KG

Full Container

Weight in KG

Container Length in

Cm

Container Width in Cm

Container Height in Cm

Cradboard Box YES Pieces 50 Scrap 0.50 1.728 86.90 120 100 121

Tote YES Lbs 120 Returnable Container 1.20 1.608 194.16 120 100 121

Cart YES Pieces 400 Returnable Container 18.00 1.652 678.80 120 100 121

GOW YES Pieces 25 Scrap 1.60 1.624 42.20 120 100 121

Gon NO Pieces 12 Scrap 22.40 1.484 40.21 100 66 141.5

Spool YES Meters 500 Scrap 10.00 350.00 100 66 141.5

Tote YES Lbs 300 Returnable Container 1.2 1.444 434.40 100 66 141.5

Cradboard Box YES Pieces 50 Scrap 0.50 2.934 147.20 120 60 121

Gon NO Pieces 100 Scrap 22.40 3.082 330.60 120 100 121

Cart YES Pieces 100 Returnable Container 18.00 2.262 244.20 100 66 141.5

Tote YES Lbs 200 Returnable Container 1.2 2.778 556.80 138 128 143

Information about the Packaging ContainerStep 5

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PFEP – Shipping Information

Order Frequency Lead Times Carrier Shipment Frequency Min Shipment Size Number of pieces

per Shipment Is Inspection

Required ?

19 20 21 22 23 24 25

Order Frequency

Delivery Lead Time -

Days

Transportation Carrier

Shipment Frequency

Min Shipment

Size

Number of Pieces per Min

Shipment

Inspection Required?

Daily 1 Bradley Express Weekly Box 50 NO

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



1 / Week 3 UPS Weekly Pallet 480 NO

When Needed 10 FedEx Weekly Spool 500 YES



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

Shipping Information

Purchased Parts and/or Finished Goods

Step 6

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Developing the PFEP Plan

Once you populate the data base you can start planning 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

Step 7

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Size of Containers

Identify if each container is “Line Ready” – YES or NO Small box, easy to lift Less than 12 KG (30 lbs)Step 7

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Does the part need repacking?

Or the container is Line Ready?

Step 8

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Should we start talking to our Supplier about delivering parts in Line Ready containers?

Step 8

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Why do we spending so much money on packaging by Suppliers when we do not use it and do not need it?

Step 8

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A B C – Analysis of all Current Parts

Are all current parts in the Data Base active? When was the last time some of these parts were used? Which ones are obsolete or not-active?

Number of Codes

Number ofNot-Active Codes – 65%

Number of Active Codes – 35%

Number of Codes Number of Codes used in last 4 Months

– 20%

Number of Codes NOT used in last 4 Months

– 80%

Step 9

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PFEP - Keys to Success

Controlled maintenance of a single database 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)

Step 10

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Changing the World. One Transformation at a timeThis presentation is an intellectual property of W3 Group Canada Inc.

No parts of this document can be copied or reproducedwithout written permission from:

Marek PiatkowskiW3 Group Canada Inc.iPhone: 416-235-2631

Cell: 248-207-0416

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