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Materials Strategy - PFEP

                    Plan for Every Part



                                    Marek Piatkowski
                                      December 2010


Marek Piatkowski – FSP Consulting
                                                       1
1. Creating Plan-for-Every- Part




                        PFEP
           1.
                        Plan-for-Every-Part

                                                                         2.    Parts Storage -
                                                                               Supermarkets




                                                          Creating Purchased
                                                          Parts Supermarket




                                            Kanban                              Material
                                       3.   Based                        4.     Delivery
                                            Pull Signal                         Systems




   Marek Piatkowski – FSP Consulting
                                                                                                 2
Start collecting Information for (PFEP)

      PFEP is a data base.
      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 ©




   Marek Piatkowski – FSP Consulting
                                                                                3
Establishing PFEP – How much detail?

                 Part number                Container type
                 Description                Length
                 Daily usage                Width
                 Point of use location      Height
                 Storage location           Weight
                 Order frequency            Standard pack quantity
                 Supplier name              Delivery frequency
                 Supplier city              Carrier
                 Supplier country           Transit time
                 …                          …




   Marek Piatkowski – FSP Consulting
                                                                       4
Develop the PFEP Plan

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




   Marek Piatkowski – FSP Consulting
                                                             5
Does the part need Repacking ?
Marek Piatkowski – FSP Consulting
                                                            6
Si o No ?
Marek Piatkowski – FSP Consulting
                                                7
Marek Piatkowski – FSP Consulting
                                    8
Develop the PFEP Plan

      For every part identify inventory levels required at each machine
       and work station
           - how many boxes / containers?
           - Min = 2 hours of inventory
      If parts must be re-packaged
            - select a new container type
            - define and minimize Standard Pack Quantities
      Identify inventory levels (min/max) at each storage location and
       Supermarket




   Marek Piatkowski – FSP Consulting
                                                                           9
Plan-for-Every-Part - Data Base
   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
  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

   Marek Piatkowski – FSP Consulting
                                                                                                                                                                     10
Lean Transformation Solutions
                                                             Marek Piatkowski
                                                         F.S.P. Consulting Inc.
                                                         F.S.P.

                                                            VM: 416-235-2631
                                                                  416-235-
                                                            Cell: 248-207-0416
                                                                  248-207-
                                                 Marek.Piatkowski@rogers.com
                                                      www.TWI-
                                                      www.TWI-Network.com


Marek Piatkowski – FSP Consulting
                                                                                  11

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Pfep introduction

  • 1. Materials Strategy - PFEP Plan for Every Part Marek Piatkowski December 2010 Marek Piatkowski – FSP Consulting 1
  • 2. 1. Creating Plan-for-Every- Part PFEP 1. Plan-for-Every-Part 2. Parts Storage - Supermarkets Creating Purchased Parts Supermarket Kanban Material 3. Based 4. Delivery Pull Signal Systems Marek Piatkowski – FSP Consulting 2
  • 3. Start collecting Information for (PFEP)  PFEP is a data base.  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 © Marek Piatkowski – FSP Consulting 3
  • 4. Establishing PFEP – How much detail?  Part number  Container type  Description  Length  Daily usage  Width  Point of use location  Height  Storage location  Weight  Order frequency  Standard pack quantity  Supplier name  Delivery frequency  Supplier city  Carrier  Supplier country  Transit time  …  … Marek Piatkowski – FSP Consulting 4
  • 5. Develop the PFEP Plan Identify if each container is “Line Ready” – YES or NO  Small box, easy to lift  Less than 12 KG (30 lbs) Marek Piatkowski – FSP Consulting 5
  • 6. Does the part need Repacking ? Marek Piatkowski – FSP Consulting 6
  • 7. Si o No ? Marek Piatkowski – FSP Consulting 7
  • 8. Marek Piatkowski – FSP Consulting 8
  • 9. Develop the PFEP Plan  For every part identify inventory levels required at each machine and work station - how many boxes / containers? - Min = 2 hours of inventory  If parts must be re-packaged - select a new container type - define and minimize Standard Pack Quantities  Identify inventory levels (min/max) at each storage location and Supermarket Marek Piatkowski – FSP Consulting 9
  • 10. Plan-for-Every-Part - Data Base 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 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 Marek Piatkowski – FSP Consulting 10
  • 11. Lean Transformation Solutions Marek Piatkowski F.S.P. Consulting Inc. F.S.P. VM: 416-235-2631 416-235- Cell: 248-207-0416 248-207- Marek.Piatkowski@rogers.com www.TWI- www.TWI-Network.com Marek Piatkowski – FSP Consulting 11