1st Edition

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

By Tim Conrad, Robyn Rooks Copyright 2011
    144 Pages 61 B/W Illustrations
    by Productivity Press

    144 Pages
    by Productivity Press

    A Plan for Every Part (PFEP) is all about determining the right part at the right time, in the quantity needed. Turbo Flow: Using Plan for Every Part (PFEP) to Turbo Charge Your Supply Chain explains how to take this detailed inventory plan from the manufacturing arena and apply it to boost performance and cost efficiencies in your supply chain. It explains how to use PFEP to improve management of your raw materials, WIP, and finished goods inventories.

    Tapping into two decades of combined experience at Toyota Motor Manufacturing, the authors explains how to use PFEP to determine how much you need to build, the proper frequency for deliveries, how often you need to pick up from suppliers, and how much inventory you require.

    • Presents an overview of PFEP for finished goods
    • Discusses internal route planning and design using PFEP data
    • Details external logistics and synchronization of manufacturing, logistics, and inventory cycles

    For those willing to fundamentally change the way they do business, this book will light the path to more efficient and profitable supply chain management.

    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
    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

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


    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