1. Materials Strategy - PFEP
Plan for Every Part
Marek Piatkowski
December 2010
Marek Piatkowski – FSP Consulting
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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
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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
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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
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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)
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6. Does the part need Repacking ?
Marek Piatkowski – FSP Consulting
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7. Si o No ?
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8. Marek Piatkowski – FSP Consulting
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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
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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
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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
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