Building a Plan for Every Part (PFEP) is one of the most effective ways to create standardization in an ordering and delivery process and optimize material flow. Breakthrough results in on-time-delivery, coverage, and cost reduction can be achieved through this discipline, but how do you do it? In this 1-hour webinar from the LeanCor Consulting team, learn the critical components of PFEP that will ensure delivery of the Right part, at the Right time, in the Right quantity. *This webinar is part of a special “Go to the Gemba” series where we interview different industry supply chain professionals about how they use lean principles and tools to solve their challenges. We Will Explore: How to collect the PFEP data necessary to make informed decisions about transportation, packaging, inventory, placement, ordering quantities, and handling. How to successfully implement PFEP in your operations How PFEP can stimulate an environment of doing the right thing first and lay the foundation for continuous improvement

1. Optimize your supply chain processes. Decrease total cost. Copyright © LeanCor 2015
How to Create Standardization in Material Flow Ordering

2. Copyright © LeanCor 2015
Regional Vice President,
LeanCor Supply Chain Group
Instructor,
University of Kentucky, Lean
Enterprise Institute
dbrowning@leancor.com
Career Focus:
Supply chain and logistics including
transportation management, logistics network
and route designs, PFEP and material flow, ROI
assessments, lean cross-dock and distribution
center projects and people development
Currently Responsible For:
Managing and supporting active lean supply
chain projects, facilitating LeanCor Training
and Education events and Kaizen workshops,
managing the Lean Deployment central
region, and working with current and future
clients to develop business opportunities.
Industry Group Speaker:
AME, CSCMP, WERC, UK Gatton College of
Business, Lean Enterprise Institute, Honda
Lean Network

3. Copyright © LeanCor 2015
Material Flow Engineer,
LeanCor Supply Chain Group
hsadek@leancor.com
Career Focus:
Supply chain and logistics including
transportation management, logistics
network and route designs, PFEP and material
flow, ROI assessments, lean cross-dock and
distribution center projects and people
development
Currently Responsible For:
Driving LeanCor’s continued growth in
utilizing and maintaining PFEP data to
implement material flow improvements
throughout the customer’s manufacturing
plant; Lean Coach in LeanCor’s Certified
Online Lean Training for Leaders
Industry Experience:
Supply Chain Business Analyst and Gemba
Kanri Support for Nissan North America

4. Copyright © LeanCor 2015
 Lean, supply chain, six
sigma, and leadership
courses that develop
people capability and
problem solving skills
while building a culture of
operational excellence.
 Project-based, end-to-
end supply chain
solutions that improve
your processes, reduce
inventory and Total Cost,
and optimize your
network.
 Custom, outsourced
transportation
management and
warehousing
solutions that optimize
material flow, and exceed
your business goals.
Trusted supply chain partner that specializes in lean principles to
deliver operational improvement. Three divisions:

5. Copyright © LeanCor 2015
Plan for every part (PFEP) is a database integrated with the
enterprise resource (ERP) system; that monitors and controls the
movement of parts within the supply chain network until the
point of use. It details and centralizes each part’s complete
information for increased visibility.

6. Copyright © LeanCor 2015
 PFEP system defines and sustains information about each part in
the process: where it comes from; How it is delivered, When and
how often, how it should be stored and packaged, the point of
use and when to replenish.
 A well designed and maintained PFEP System significantly
reduces material shortages, inventories, supply chain
complexities and costs.
Demand
Drives Production
On-Time Delivery
Drives Schedule
Consumption
Drives Replenishment

7. Copyright © LeanCor 2015
 Corporate and Plant Logistics
 Purchasing & Planners
 Material Flow Engineers
 Industrial Engineers
 Process Techs
 Suppliers
 Repack Operation
 Packaging Engineers
POLL: Who would benefit most from
PFEP at your organization?
Submit your answer in the Question box.

8. Copyright © LeanCor 2015

9. Copyright © LeanCor 2015
 Cross-functional team effort
 One part at a time
 Group Parts into categories
 Load data in the smallest
element possible
 Usage details
 Supplier Details
 Delivery methods and frequency
 Perform a Trial Run

10. Copyright © LeanCor 2015
Download the full case study: leancor.com/industries-served-and-case-studies/

11. Copyright © LeanCor 2015
Excel
- Small Facility
- Manual Entry Updates
- Complex Formulas
- One user only at a time
- Hard and Risky to maintain
- Limited Options
PFEP Systems
- Large Facility
- Automatic Updates
- No seen formulas
- Multi-user capabilities
- Easy and less risk to maintain
- Wide range of options
POLL: What PFEP technology do you use?
Select all that apply.

12. Copyright © LeanCor 2015
 Appoint a PFEP Handler
 Fewer PFEP handlers will definitely
results in a more accurate PFEP
 Create a PFEP Change/Add Request Form
 Institute a guideline for PFEP documentation and approval
process before it appears on the shop floor
 Store the current updated PFEP in one central, accessible
location (Read Only).

13. Copyright © LeanCor 2015
 False information across the board
 Being active instead of proactive
 Failure to deliver the parts on time causing downtime
 The process of ordering materials in the exact
quantities becomes complicated
 Parts exceeding WH capacity & inventory level
fluctuates (Ordering Vs Consumption)
 Expedite transportation costs hit the roof
 Lost visibility and control over part delivery
POLL: What analysis do you
perform on your PFEP?
Submit your answer in the
Question box.

14. Copyright © LeanCor 2015
Right Part Right Quantity
Right Time
Align responsibilities to
Fully utilize existing staff
Establishing merge deliveries and
DTL (Direct To Line) internal material flow
Order parts based on actual line
Usage Creating a pull system
Ideally to Eliminate in-Plant WH
(Reduction of Gains and Loses)
Improve shop floor supervisor
Skill set
By creating marshaling
lanes to improve
material accuracy and
check plan is well
executed
(Hot Calls Control)
POLL: Which of these
advantages do you
need most?

15. Copyright © LeanCor 2015
 Based on the Shingo-Award winning book,
PEOPLE
 Leverage lean principles to become a
more effective leader, build teams, and
drive operational excellence.
 Start today:
◦ www.leancor.com/online-lean-training/
 Coming soon: 90-Min Lean Fundamentals!
Exclusive 20%
Discount Code
for Webinar
Attendees!
Use
“leanleader”
at checkout!

16. Copyright © LeanCor 2015
Next Webinar:
Inventory Reduction
WED, June 24 | 11:00 – 12:00 EDT
Register Now!
www.leancor.com/events

17. Copyright © LeanCor 2015
Derek Browning
dbrowning@leancor.com
859.652.1812
Let’s connect on
Hussein Sadek
hsadek@leancor.com
712.336.6776
Let’s connect on