PFEP (Plan For Every Part) in Practice —— A Single-Page Material Parameter Sheet for Lean Logistics

1. PFEP: Plan For Every Part is Not an Excel Obsession

Kitting rate 85%, production lines are full but always missing that one part, ERP shows inventory but it can't be found on-site — Often the root cause is not slow purchasing, but the lack of PFEP (Plan For Every Part, plan for each part) or a dual-track between PFEP and the actual site.

PFEP is a material master data + logistics parameter single-page sheet in lean logistics: one record per material number, answering where it comes from, where it is stored, how it is transported, how much is needed, and who is responsible.

2. Differences Between PFEP, BOM, and Material Master Data

PFEP references material numbers but does not replace BOM; one PFEP line = one factory + material number (multiple factories require separate lines).

3. Standard Fields of PFEP (22 Core Items)

1. Part Number / Description
2. Supplier / Manufacturing Source
3. Production Line / Consumption Process
4. Packaging Type / Standard Packaging Quantity C
5. Line-side Storage Location / Supermarket Position
6. Min/Max Line-side Inventory
7. Number of Kanban Cards (if pull production)
8. Replenishment Method (Kanban/MRP/Direct Delivery)
9. Transportation Method (Water Spider/AGV/Forklift)
10. Transportation Cycle / Frequency
11. Receiving Inspection Requirements (IQC Skip Lot?)
12. Storage Conditions / Shelf Life
13. Substitute Material / Break Point
14. Responsible Person (Logistics/Purchasing/Quality)
15. Container Number / Returnable Packaging
16. Weight/Volume per Unit (for layout)
17. Value Density (ABC)
18. Customer-Supplied / Consignment
19. Emergency Contact / Alternative Supplier
20. Last PFEP Review Date
21. ECN Association
22. Remarks (Special Handling Requirements)

There's no need to implement all 22 columns at once — start with 10 columns and iterate.

4. Who Maintains PFEP? How to Change It

Change Control: New material numbers must not go to the line-side without PFEP; PFEP must be updated within 48 hours of ECN and labels must be synchronized on-site.

5. From PFEP to Kanban Quantity

Once D, L, C in PFEP are determined:

Kanban N = (D × L × (1+S)) / C

This ties in with the Kanban and Supermarket (7.1.3) article; PFEP is the source of parameters for kanban calculation.

6. PFEP and PFEP Audits (Gemba)

Monthly audit of 10% of material numbers on-site:

• Is the storage location consistent with PFEP?
• Is the standard packaging quantity C consistent?
• Is the actual replenishment method in line with PFEP (or is it a "temporary forklift")?

Discrepancies should be entered into the QRQC or logistics improvement pool.

7. Relationship with ERP/MRP

• MRP runs planned orders; PFEP defines how to execute on-site
• Repetitive parts, high turnover → PFEP prioritizes pull; MRP only monitors
• Long lead time, imported parts → PFEP still records LT and alternatives; MRP is the main planner

Avoid expanding ERP fields to 100 columns that are not used on-site — PFEP can be the authoritative logistics system.

8. New Project / New Line Introduction

Complete the initial PFEP before the Gate in the NPI stage:

• First version of PFEP within 72 hours after the trial production BOM is frozen
• Revise PFEP based on actual LT, Min/Max after trial production
• Ensure alignment of PFEP, layout diagram, and water spider routes before SOP

9. Common Failures

10. 90-Day Implementation

11. Integration with Layout Series

The article 7.4.2 Layout and Logistics Quality addresses flow lines and waste; Water Spider, Kanban (7.1.3) addresses pull execution. PFEP provides C, Min/Max, and routes for each material — the three articles together ensure from diagram to data to on-site execution.

12. Considerations for Multi-Factory Replication

Within the group, the same material number in different factories must be separated into different PFEP lines: suppliers, LT, line-side storage locations, and packaging C may differ. Do not force the headquarters PFEP without local Gemba verification.

13. PFEP Data Quality KPIs

• PFEP Coverage Rate = Number of production material numbers with PFEP / Total number of material numbers to be covered
• Audit Compliance Rate = Number of consistent items on-site / Number of sampled items
• Material Shortage Event PFEP Hit Rate = Proportion of material numbers with defined Min/Max in PFEP among those experiencing shortages

Target: Coverage Rate ≥95%, Compliance Rate ≥90% before full-scale pull production implementation.

14. PFEP and IQC Strategy Column

PFEP must specify IQC method for each material: normal inspection, skip lot, no inspection, supplier PPAP locked. The Quality Department and Logistics co-sign no-inspection materials (usually ≤5% and low risk). Any change in IQC strategy must update PFEP and clear old labels on-site.

15. Containers and Returnable Packaging

PFEP records container numbers, stacking layers, and empty container return routes, which are directly related to water spider and AGV route design. Omitting container information can lead to full containers at the line-side that cannot be returned, causing false material shortages.

16. Grouping of Excel Template Fields (Implementation Order)

First Batch (10 Columns): Material number, description, production line, storage location, C, Min, Max, replenishment method, responsible person, review date

Second Batch: Supplier, LT, number of kanban cards, transportation method, IQC

Third Batch: Remaining advanced fields

17. Interface with Water Spider/AGV Articles (7.4 Series)

The route and frequency of water spiders come from the consumption points and C in PFEP; AGV tasks are triggered by the replenishment method = electronic kanban/AGV in PFEP. AGV projects without PFEP often run full but empty.

18. Series Map (7.4 Lean Logistics)

Recommended Implementation Order: PFEP → Layout → Kanban Calculation → Water Spider/AGV → WIP Strategy Review.

A solid PFEP provides a unified data foundation for the 7.4 Layout, Water Spider, Kanban series — otherwise, logistics improvements will always be in "firefighting" mode.

Randomly select one material number that is short on the day: Can you find the Min/Max, storage location, and replenishment method in PFEP within 1 minute?

Knowledge code: 7.4.1

Version: v20260702

Author: Quality Think Tank Quality Think Tank is dedicated to providing systematic professional knowledge, methodologies, and practical tools for quality management practitioners, helping companies continuously improve their quality capabilities.