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
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?
Breaking Down the "Every"
The Toyota Cost Reduction Model
Ownership of the PFEP
What Do I Need to Build What I Need?
Takt Time Calculation Example
The Role of the Supplier
What Do Suppliers Need?
Understanding the Bill of Material to Populate the PFEP
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
Supply Chain Cycle Time
Using PFEP for Internal Planning
Internal Route Planning
Coupled versus Decoupled Delivery Routes
A Pull-Card Market
Rules for Supermarket and Usage Point Flow Racks
Receiving/Shipping Address System
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
True Assembly-Based Production
The Role of Production Control
Supply Chain Complexity
Supply Chain Integration
Other Supply Chain Considerations
144 pages; ISBN 9781439883709
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Title: Turbo Flow
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