1. PFEP – Plan for Every Part
Definitions
Marek Piatkowski – August 2016 1

2. Introduction - Marek Piatkowski
Professional Background
Toyota Motor Manufacturing Canada (TMMC) - Cambridge, Ontario from
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

4. 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

5. 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. Inventory Analyst Step 1 Key Points - Responsibilities Reasons
Maintenance and control of max/min levels, lead times, order quantities, re- order points, etc… in SAP/MRP system
Maintenance of BOM and Pick Lists
Management of new and obsolete parts and components
Plan-for-Every-Part (PFEP)
Introduction and maintenance of a Kanban cards and system
Inventory policies (levels, controls and management)
To maintain and to keep all information in the system up to date and to provide feedback to management
Update information at least monthly
Add new parts and remove obsolete once from the system
Single source of information
Kanban cars get lost and Kanban cards must be updated on regularr basis
To review inventory information at monthly Sales and Operations meetings

7. Identify the Type of Parts in your PFEP Data Base
Purchased Parts
Finished Goods
Step 2

8. 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. 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. PFEP – Information about the Part
Purchased Parts
Finished Goods
Step 4
Part number
Customer Part Number
Part Description
Part Name
Model/Color

11. PFEP – Information about the Container
Purchased Parts and/or Finished Goods
Step 5
Container Type
Standard Container Quantity
Unit of Measure
Quantity per Container
Container Instructions
Container Dimensions and weight

12. PFEP – Shipping Information
Purchased Parts and/or Finished Goods
Step 6
Order Frequency
Lead Times
Carrier
Shipment Frequency
Min Shipment Size
Number of pieces per Shipment
Is Inspection Required ?

13. 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. Size of Containers Step 7
Identify if each container is “Line Ready” – YES or NO
Small box, easy to lift
Less than 12 KG (30 lbs)
Step 7

15. Step 8
Does the part need repacking?
Or the container is Line Ready?

16. Step 8
Should we start talking to our Supplier about delivering parts in Line Ready containers?

17. Step 8
Why do we spending so much money on packaging by Suppliers when we do not use it and do not need it?

18. 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?
Step 9

19. PFEP - Keys to Success Step 10
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. 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.
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