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

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

Kitting rate 85%, line-side 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 lack of PFEP (Plan For Every Part) or PFEP and on-site operations running on parallel tracks.

PFEP is the material master data + logistics parameter one-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 the 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. Kanban Card Quantity (if pull system)
8. Replenishment Method (kanban/MRP/direct delivery)
9. Transportation Method (water spider/AGV/forklift)
10. Transportation Cycle / Frequency
11. Receipt Inspection Requirements (IQC skip-lot?)
12. Storage Conditions / Shelf Life
13. Substitute Material / Breakpoints
14. Responsible Person (logistics/purchasing/quality)
15. Container Number / Returnable Packaging
16. Unit Weight / Volume (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

Change Control: New material numbers must not go on-line without PFEP; PFEP must be updated within 48 hours of ECN and labels updated 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 packaging quantity C consistent?
• Is the actual replenishment method following PFEP (or "temporary forklift")?

Discrepancies go into the QRQC or logistics improvement pool.

7. Relationship with ERP/MRP

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

Avoid expanding ERP fields to 100 columns that aren't 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 phase:

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

9. Common Failures

10. 90-Day Implementation

11. Integration with Layout Series

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

12. Considerations for Multi-Factory Replication

Within the group, the same material number in different factories must have separate PFEP lines: suppliers, LT, line-side storage locations, and packaging C may differ. Do not force 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 on-site consistent items / Number of sampled items
• Material Shortage Event PFEP Hit Rate = Proportion of material numbers with defined Min/Max in PFEP for shortages

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

14. PFEP and IQC Strategy Column

PFEP must specify IQC method for each material: normal inspection, skip-lot, no inspection, supplier PPAP lock. 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 path design. Omitting container information can lead to full containers at 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, kanban N, transportation method, IQC

Third Batch: Remaining advanced fields

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

Water spider routes and frequency come from PFEP's consumption points and C; AGV tasks are triggered by PFEP's replenishment method=electronic kanban/AGV. AGV projects without PFEP often run full but empty.

18. Series Map (7.4 Lean Logistics)

Suggested 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, and kanban series — otherwise, logistics improvements will always be about "firefighting and replenishment."

Randomly select 1 material number that was short on the same day: Can the Min/Max, storage location, and replenishment method be found within 1 minute in the PFEP?

Knowledge Number: 7.4.1

Version: v20260702

Author: Quality Excellence Think Tank Quality Excellence Think Tank is dedicated to providing systematic professional knowledge, methodologies, and practical tools for quality management practitioners, supporting continuous improvement in enterprise quality capabilities.