Turbo Flow Using Plan for Every Part (PFEP) to Turbo Charge Your Supply Chain

Toyota Practiced Lean before It Was Called "Lean"
Origins of a New Idea
Improving on the New Paradigm
     Moving on Toward PFEP

Understanding Plan for Every Part
Inventory Buffers Explained
Understanding Waste
What Should I Build Today?
How Much Inventory Do I Need?
When and Where Do I Need the Inventory?

Management of PFEP
Who Owns the PFEP?
     Every Part
          Breaking Down the "Every"
          The Toyota Cost Reduction Model
Ownership of the PFEP
What Do I Need to Build What I Need?
Takt Time
     Takt Time Calculation Example
The Role of the Supplier
     What Do Suppliers Need?
Understanding the Bill of Material to Populate the PFEP

Managing Loops
Value Stream Mapping
ABCs of the Part Number
Life Cycle Code
The Right Quantity—Daily Usage Rate
Why Do I Need All This Stuff?

Finished Goods Planning
Manufacturing Planning Time
     Manufacturing Frequency
     Transportation Time
     Put-Away Time
     Buffer (Safety)
Supply Chain Cycle Time

Using PFEP for Internal Planning
Internal Route Planning
     Layout
Coupled versus Decoupled Delivery Routes
     Address System
     A Pull-Card Market
     Rules for Supermarket and Usage Point Flow Racks
     Call Market
     Receiving/Shipping Address System
     Other Areas
Safety First—If It Is Not Safe, Do Not Do It!

Delivering Parts to the Operators’ Fingertips
Small Part Delivery (Known Time—Unknown Quantity)
Kanban Calculation Examples
Understanding the Breakdown of the Product Mix
Planning at the Cell Level
     Delivering the Parts to the Cell
     Calculating Delivery Frequency
     Calculating the Number of Kanban Delivered
     Making Your Routes More Efficient
Call Part Delivery (Known Quantity—Unknown Time)
Sequence Part Delivery (Known Time—Unknown Quantity)

Planning: Supporting Processes
Modeling Our Scheduling Process
Just-in-Time Scheduling
True Assembly-Based Production
Batch-Supporting Process
The Role of Production Control
Budgeting

Supply Chain Complexity
Supply Chain Integration
Inventory Impact
Logistics Cost
Other Supply Chain Considerations

Biography

Tim Conrad

This book defines the role of production control and supply chain management from both a broad view and a ‘nuts-and-bolts, how-to’ perspective. The Plan for Every Part (PFEP) process will help your organization cut across the traditional silos of distribution, manufacturing, purchasing and logistics to create a transparent process that will enable you to truly supply the right part at the right time in the quantity needed.
—Mike Hoseus, Co-Author of Toyota Culture, Former General Manager, Toyota Motor Manufacturing Kentucky

Tim and Robyn have taken the PFEP to another level. Their detailed approach of applying PFEP principles to the entire supply chain will help any company eliminate waste and make progress on their lean journey.
—Earl D. Wilson, Co-Author of Making Materials Flow, President, Wilson Lean Concepts, Inc.

Robyn and Tim so humbly point out that every part has a story, and you have to listen to that story. This is a subtle, but very important point…. Plan for Every Part (PFEP) builds the foundation for supply chain excellence and if truly embraced, will lead to a sustainable competitive advantage with your customers.
—John Bohenick, Executive, Consultant, Board Director, & Former President of the Gates Corporation

A must read for any organization creating a lean enterprise by improving speed in the supply chain.
—Tribby Warfield, Gates Corporation, President, Power Transmission Division North America