Plan-for-Every-Part (PFEP) - Introduction November 2016
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This document provides information and guidance on developing a Plan for Every Part (PFEP) database. It recommends establishing an Inventory Analyst role to be responsible for the PFEP database. It describes collecting information for the database on parts, containers, shipping, and developing a plan based on the data. The goal is to gather and maintain updated information on all material used in processes to facilitate planning and inventory management.
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Plan-for-Every-Part (PFEP) - Introduction November 2016
- 1. 1Marek.Piatkowski@Rogers.com Plan-for-Every- Part (PFEP) Definitions Thinkingwin, Win, WIN PFEP – Plan for Every Part Definitions Marek Piatkowski – August 2016 Thinkingwin, Win, WIN
- 2. 2Marek.Piatkowski@Rogers.com Plan-for-Every- Part (PFEP) Definitions Thinkingwin, Win, WIN 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
- 4. 4Marek.Piatkowski@Rogers.com Plan-for-Every- Part (PFEP) Definitions Thinkingwin, Win, WIN 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
- 5. 5Marek.Piatkowski@Rogers.com Plan-for-Every- Part (PFEP) Definitions Thinkingwin, Win, WIN 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
- 6. 6Marek.Piatkowski@Rogers.com Plan-for-Every- Part (PFEP) Definitions Thinkingwin, Win, WIN 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
- 7. 7Marek.Piatkowski@Rogers.com Plan-for-Every- Part (PFEP) Definitions Thinkingwin, Win, WIN Identify the Type of Parts in your PFEP Data Base Finished Goods Purchased Parts Step 2
- 8. 8Marek.Piatkowski@Rogers.com Plan-for-Every- Part (PFEP) Definitions Thinkingwin, Win, WIN 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
- 9. 9Marek.Piatkowski@Rogers.com Plan-for-Every- Part (PFEP) Definitions Thinkingwin, Win, WIN 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
- 10. 10Marek.Piatkowski@Rogers.com Plan-for-Every- Part (PFEP) Definitions Thinkingwin, Win, WIN 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
- 11. 11Marek.Piatkowski@Rogers.com Plan-for-Every- Part (PFEP) Definitions Thinkingwin, Win, WIN 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
- 12. 12Marek.Piatkowski@Rogers.com Plan-for-Every- Part (PFEP) Definitions Thinkingwin, Win, WIN 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 Daily 1 Bradley Express Weekly Box 400 NO Daily 1 Bradley Express Weekly Box 25 NO 1 / Week 3 UPS Weekly Pallet 480 NO When Needed 10 FedEx Weekly Spool 500 YES Daily 1 Bradley Express Weekly Box 300 NO 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 Shipping Information Purchased Parts and/or Finished Goods Step 6
- 13. 13Marek.Piatkowski@Rogers.com Plan-for-Every- Part (PFEP) Definitions Thinkingwin, Win, WIN 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
- 14. 14Marek.Piatkowski@Rogers.com Plan-for-Every- Part (PFEP) Definitions Thinkingwin, Win, WIN 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
- 15. 15Marek.Piatkowski@Rogers.com Plan-for-Every- Part (PFEP) Definitions Thinkingwin, Win, WIN Does the part need repacking? Or the container is Line Ready? Step 8
- 16. 16Marek.Piatkowski@Rogers.com Plan-for-Every- Part (PFEP) Definitions Thinkingwin, Win, WIN Should we start talking to our Supplier about delivering parts in Line Ready containers? Step 8
- 17. 17Marek.Piatkowski@Rogers.com Plan-for-Every- Part (PFEP) Definitions Thinkingwin, Win, WIN Why do we spending so much money on packaging by Suppliers when we do not use it and do not need it? Step 8
- 18. 18Marek.Piatkowski@Rogers.com Plan-for-Every- Part (PFEP) Definitions Thinkingwin, Win, WIN 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
- 19. 19Marek.Piatkowski@Rogers.com Plan-for-Every- Part (PFEP) Definitions Thinkingwin, Win, WIN 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
- 20. 20Marek.Piatkowski@Rogers.com Plan-for-Every- Part (PFEP) Definitions Thinkingwin, Win, WIN 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
- 21. 21Marek.Piatkowski@Rogers.com Plan-for-Every- Part (PFEP) Definitions Thinkingwin, Win, WIN Presentations in this Workshop 1. Log in to: www.slideshare.net 2. Type in my name in search area: Marek Piatkowski 3. Select a presentation you want to see 4. Learn and Enjoy