Pfep introduction
- 1. Materials Strategy - PFEP Plan for Every Part Marek Piatkowski December 2010 Marek Piatkowski – FSP Consulting 1
- 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 2
- 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 3
- 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 4
- 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) Marek Piatkowski – FSP Consulting 5
- 6. Does the part need Repacking ? Marek Piatkowski – FSP Consulting 6
- 7. Si o No ? Marek Piatkowski – FSP Consulting 7
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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 9
- 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 10
- 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 11