Plan for Every Part

Plan for every part (PFEP) is the blueprint for effectively managing logistics and manufacturing aspects of a part (for Finished Goods as well as Raw Materials/Purchased Components). A properly done PFEP is a great framework for streamlining material flow for the part as well as synchronizing supply chain. A “Plan For Every Part” is a plan to make sure

Right part is available where needed at the right time in the right quantity

 

Our experience suggests that PFEP assessments should be done as part of New Product Introduction related Manufacturing and Logistics planning as well as routinely and continuously to monitor changes to manufacturing/ordering patterns so that appropriate master data adjustments can be made.

The figure below shows information as well as material flow in a typical supply chain – from suppliers providing raw materials/components to manufacturing operations and distribution of finished goods to different customer locations.

 

 

Some of the more common data elements for “Plan For Every Part” include the following

 

Part Overview

  • Part Number
  • Part Name
  • Length, Width, Height (LWH)
  • LWH Unit
  • Net weight and weight unit
  • ABC Classification

 

Supplier Information

  • Supplier(s)
  • Supplier Shipment Location and Address
  • Frequency of Material Ordered from Supplier
  • Carrier
  • Transit Time
  • Delivery route
  • Delivery method
  • Delivery frequency

 

Storage Plan

  • Warehouse Storage Area (Supermarket)
  • Storage bin
  • Storage strategy

 

Inventory Plan

  • Daily Usage
  • Minimum order quantity
  • Reorder point
  • Minimum number of containers
  • Maximum number of containers
  • Consumption (per hour, day, week, month)
  • Buffer stock
  • Cycle stock
  • Safety stock
  • Target max cost of inventory

 

Manufacturing Operations Plan

  • Usage Location(s)
  • Usage at Location (per hour, shift, day, week, month)
  • Max inventory at usage point
  • Container Type (Kanban cart)
  • Container Length, Height, Width
  • Container Weight
  • Total Package Weight
  • Standard Container Quantity
  • Containers Usage (per hour, shift, day, week)
  • Returnable container location
  • Number of Kanban cards in the loop
  • Name of Kanban loop