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