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Set up PFEP Database

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Set up an electronic record-keeping system where all material-related information will be stored. This will probably be a spreadsheet. This is a critical step, as there is too much data to manage the Kanban and Material data manually. Do not rely on your ERP/MRP system alone for this step, as it lacks the analysis capability of a spreadsheet.

Select PFEP Database

Select the software to build the PFEP database. Whether you choose to use a spreadsheet or commercial software to store the PEFP information, each one has its pros and cons. Just make sure you have a solid plan to deal with the maintenance of this critical data.

Train in Database Use

Train all Administrators, Super Users, and Users in the capabilities, features, and characteristics of the PFEP database. Same as above each choice will require the users to know what they are doing when they get their hands on the data. The higher power of a commercial system will come at the cost of a steeper learning curve and reduced flexibility.

Electronic Data Available?

Identify the main data sources. The most common source will be your ERP/MRP system. Smaller companies that are just getting started may not have the data in an ERP system. Here you and your team are facing a decision that boils down to manual entry or electronic data transfer from your ERP system.

No | Collect Data Manually

Collect the Item Master data from all sources manually. If electronic data is not available, roll up your sleeves and start organizing the data collection. There will be a lot of manual entry to do.

Yes | Populate Initial PFEP Data

Populate the PFEP database with all the basic required information to start building the replenishment profiles. Download this data electronically from your existing manufacturing system or other electronic sources (preferred).

Review Initial Data as a Team

Review the data with people who know the material and part numbers. We have not found a better way to make sure that our data is good.

Identify and Flag All Make Parts

Identify all manufactured parts in the PFEP database. Are there internally manufactured parts on the list? If so, you need to flag them as they will require a different treatment from the purchased parts on the list.

Enter Test KANBAN Chain

Test the PFEP database by entering a test Material Flow chain for calculations and tag printing. In order to get familiar with the Kanban sizing aspect of PFEP and to test some sample data, it is a good practice to enter a test Material Flow chain into the worksheet.

Assign KANBAN Chain Code to Test Parts

Test the Material Flow chain above to other part numbers that have the same chain. The Material Flow Chain code will then need to be assigned to one or more part numbers. The calculation is automatic.

Validate Sizing Calculations

Confirm the test data calculations by duplicating them manually. Make sure that the MMMM team understands clearly how the calculated quantities are derived.