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Turbo Flow

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

Turbo Flow by Tim Conrad
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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

CRC Press; November 2010
144 pages; ISBN 9781439883709
Read online, or download in secure EPUB or secure PDF format
Title: Turbo Flow
Author: Tim Conrad; Robyn Rooks
 
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