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Materials Strategy - PFEP

Plan for Every Part

Marek Piatkowski
December 2010

Marek Piatkowski FSP Consulting


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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


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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


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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


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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


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Does the part need Repacking ?
Marek Piatkowski FSP Consulting
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Si o No ?
Marek Piatkowski FSP Consulting
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Marek Piatkowski FSP Consulting
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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


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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


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Lean Transformation Solutions
Marek Piatkowski
F.S.P.. Consulting Inc.
F.S.P

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

Marek Piatkowski FSP Consulting


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