pfep plan for every part - marek on lean · pdf file01.09.2012 · 1...
TRANSCRIPT
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
LEI Poland – Tomasz Koch, President
Lean Transformation Solutions, Toronto, Canada
www.TWI-Network.com
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
NumberPart Type Hand Description
Supl.
Type
Supplier
Name
Press
LineModel
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
Establish a position of an Inventory Analyst
Responsible for the PFEP
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!
Plan for Every Part
Step 1
Reasons Key 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
Plan for Every Part
Step 1 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
Identify the Type of Parts in your PFEP Data Base
Finished Goods
Plan for Every Part
Step 2 Purchased Parts
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)
Plan for Every Part
Step 3
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
…
Plan for Every Part
Step 3
PFEP – Information about the Part Plan for Every Part
Step 4 Finished Goods Purchased Parts
1 2 3 4 5
Part NumberSupplier Part
Number
Part
DescriptionPart 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 NumberCustomer
Part NumberPart
DescriptionPart 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
PFEP – Information about the Container Plan for Every Part
Step 5 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 TypeStandard
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 120Returnable
Container1.20 1.608 194.16 120 100 121
Cart YES Pieces 400Returnable
Container18.00 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 300Returnable
Container1.2 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 100Returnable
Container18.00 2.262 244.20 100 66 141.5
Tote YES Lbs 200Returnable
Container1.2 2.778 556.80 138 128 143
Information about the Packaging Container
PFEP – Shipping Information Plan for Every Part
Step 6
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
Needed10 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
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
Plan for Every Part
Step 7
Size of Containers
Identify if each container is “Line Ready” – YES or NO
Small box, easy to lift
Less than 12 KG (30 lbs)
Plan for Every Part
Step 7
Plan for Every Part
Step 7
Does the part need repacking?
Or the container is Line Ready?
Plan for Every Part
Step 7
Should we start talking to our Supplier about delivering parts in Line Ready containers?
Plan for Every Part
Step 7
Why do we spending so much money on packaging by Suppliers when we do not use it and do not need it?
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?
Plan for Every Part
Step 8
Number of Codes
Number ofNot-Active Codes – 65%
Number of Active Codes – 35%
Number of Codes Number of Codes used in last 4 Months
– 20%
Number of Codes NOT used in last 4 Months
– 80%
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)
Plan for Every Part
Step 10
Lean Transformation SolutionsThis presentation is an intellectual property of F.S.P. Consulting Inc.
No parts of this presentation can be copied or reproducedwithout a written permission from:
Marek Piatkowski F.S.P. Consulting Inc.
iPhone: 416-235-2631Cell: 248-207-0416