Pfep introduction

1. Materials Materials Strategy Strategy --PFEPPFEP
PPlan for Every Partlan for Every Part
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Marek Piatkowski –FSP Consulting
Marek Piatkowski
December 2010

2. 1. Creating Plan-for-Every-Part1. Creating Plan-for-Every-Part
Parts Storage -
Supermarkets
PFEP
Plan-for-Every-Part
1.
2.
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Marek Piatkowski –FSP Consulting
Parts Storage -
Supermarkets
Material
Delivery
Systems
3.
Kanban
Based
Pull Signal
Creating Purchased
Parts Supermarket
4.
2.

3. Start collecting Information for (PFEP)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 ©
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Marek Piatkowski –FSP Consulting
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 ©

4. Establishing PFEP Establishing PFEP ––How much detail?How much detail?Establishing PFEP Establishing PFEP ––How much detail?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
…
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Marek Piatkowski –FSP Consulting
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
…

5. Develop the PFEP PlanDevelop the PFEP Plan
Identify if each container is “Line Ready” “Line Ready” ––YES or NOYES or NO
Small box, easy to lift
Less than 12 KG (30 lbs)
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Marek Piatkowski –FSP Consulting

6. 6
Marek Piatkowski –FSP Consulting
Does the part need Repacking ?

7. 7
Marek Piatkowski –FSP Consulting
Si o No ?

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Marek Piatkowski –FSP Consulting

9. Develop the PFEP PlanDevelop 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
9
Marek Piatkowski –FSP Consulting
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

10. Plan-for-Every-Part -Data BasePlan-for-Every-Part -Data Base
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 ReinforcementRH # 1 Cross Bar Ext Luitink 4x4 0.9 1 50 1 PN-150 Supplier
FU-31600 ReinforcementLH # 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 ReinforcementRH Lower Control Arm Bracket 4x2 2 1
FU-31608 ReinforcementLH 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 ReinforcementRH Center Side Bar Ext Ridgeview SWB 1.3 2 Sub 1 PN-150 Supplier
FU-31642 ReinforcementLH 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
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Marek Piatkowski –FSP Consulting
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 ReinforcementRH # 1 Cross Bar Ext Luitink 4x4 0.9 1 50 1 PN-150 Supplier
FU-31600 ReinforcementLH # 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 ReinforcementRH Lower Control Arm Bracket 4x2 2 1
FU-31608 ReinforcementLH 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 ReinforcementRH Center Side Bar Ext Ridgeview SWB 1.3 2 Sub 1 PN-150 Supplier
FU-31642 ReinforcementLH 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

11. 11
Marek Piatkowski –FSP Consulting
Lean Transformation SolutionsLean Transformation Solutions
Marek PiatkowskiMarek Piatkowski
F.S.PF.S.P. Consulting Inc.. Consulting Inc.
VM: 416VM: 416--235235--26312631
Cell: 248Cell: 248--207207--04160416
[email protected]@rogers.com
www.TWIwww.TWI--Network.comNetwork.com