Plan-for-Every-Part (PFEP) - Introduction November 2016

1Marek.Piatkowski@Rogers.com
Plan-for-Every-
Part (PFEP)
Definitions
Thinkingwin, Win, WIN
PFEP – Plan for Every Part
Definitions
Marek Piatkowski – August 2016

Plan-for-Every-
Part (PFEP)
Definitions
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

Plan-for-Every-
Part (PFEP)
Definitions

Plan-for-Every-
Part (PFEP)
Definitions
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

Plan-for-Every-
Part (PFEP)
Definitions
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

Plan-for-Every-
Part (PFEP)
Definitions
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 information
5. 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 system
6. Inventory policies (levels, controls and
management)
Inventory Analyst
Step 1

Plan-for-Every-
Part (PFEP)
Definitions
Identify the Type of Parts in your PFEP Data Base
 Finished Goods Purchased Parts
Step 2

Plan-for-Every-
Part (PFEP)
Definitions
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

Plan-for-Every-
Part (PFEP)
Definitions
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

Plan-for-Every-
Part (PFEP)
Definitions
PFEP – Information about the Part
 Finished Goods Purchased Parts
1 2 3 4 5
Part Number
Supplier Part
Number
Part
Description
Part 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 Part
1 2 3 4 5
Part Number
Customer
Part Number
Part
Description
Part 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

Plan-for-Every-
Part (PFEP)
Definitions
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 Type
Standard
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

Plan-for-Every-
Part (PFEP)
Definitions
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

Plan-for-Every-
Part (PFEP)
Definitions
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

Plan-for-Every-
Part (PFEP)
Definitions
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

Plan-for-Every-
Part (PFEP)
Definitions
 Does the part need
repacking?
 Or the container is
Line Ready?
Step 8

Plan-for-Every-
Part (PFEP)
Definitions
 Should we start
talking to our
Supplier about
delivering parts in
Line Ready
containers?
Step 8

Plan-for-Every-
Part (PFEP)
Definitions
 Why do we
spending so much
money on packaging
by Suppliers when
we do not use it and
do not need it?
Step 8

Plan-for-Every-
Part (PFEP)
Definitions
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 of
Not-Active Codes – 65%
Number of Active
Codes– 35%
Number of Codes Number of Codes
usedin last 4 Months
– 20%
Number of Codes NOT
usedin last 4 Months
– 80%
Step 9

Plan-for-Every-
Part (PFEP)
Definitions
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

Plan-for-Every-
Part (PFEP)
Definitions
Changing the World. One Transformation at a time
This presentation is an intellectual property of W3 Group Canada Inc.
No parts of this document can be copied or reproduced
without written permission from:
Marek Piatkowski
W3 Group Canada Inc.
iPhone: 416-235-2631
Cell: 248-207-0416
Marek.Piatkowski@rogers.com
http://twi-network.com

Plan-for-Every-
Part (PFEP)
Definitions
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Plan-for-Every-Part (PFEP) - Introduction November 2016

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Plan-for-Every-Part (PFEP) - Introduction November 2016