Post on 13-Jul-2015
Materials Materials Strategy Strategy -- PFEPPFEP
PPlan for Every Partlan for Every Part
1
Marek Piatkowski – FSP Consulting
Marek Piatkowski
December 2010
1. Creating Plan-for-Every- Part1. Creating Plan-for-Every- Part
Parts Storage -
Supermarkets
PFEP
Plan-for-Every-Part
1.
2.
2
Marek Piatkowski – FSP Consulting
Parts Storage -
Supermarkets
Material
Delivery
Systems
3.
Kanban
Based
Pull Signal
Creating Purchased
Parts Supermarket
4.
2.
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 ©
3
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 ©
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
…
4
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
…
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)
5
Marek Piatkowski – FSP Consulting
6
Marek Piatkowski – FSP Consulting
Does the part need Repacking ?
7
Marek Piatkowski – FSP Consulting
Si o No ?
8
Marek Piatkowski – FSP Consulting
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
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 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
10
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 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
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
Marek.Piatkowski@rogers.comMarek.Piatkowski@rogers.com
www.TWIwww.TWI--Network.comNetwork.com