Plan for Every Part, commonly called PFEP, is a structured database or planning system containing the information required to manage each material item used by the operation.
The purpose is to replace informal material knowledge with defined rules.
A good PFEP supports stable replenishment, storage, handling, packaging, and point-of-use delivery.
Typical PFEP information
A PFEP may include:
- part number;
- description;
- supplier;
- daily usage;
- container quantity;
- container type;
- storage location;
- point-of-use location;
- replenishment method;
- lead time;
- order frequency;
- ownership;
- special handling requirements.
The exact fields depend on the process.
Why PFEP matters
Material flow often becomes unstable because important information exists only in people’s heads.
Different shifts may use different container quantities.
Storage locations may change.
Replenishment frequency may be based on habit.
Packaging may not match the point-of-use need.
PFEP creates one controlled source of truth.
Connect PFEP to pull
A Pull System replenishes material based on downstream consumption.
Kanban provides the signal.
PFEP provides much of the master data needed to design those systems.
For example:
- usage rate;
- container quantity;
- replenishment frequency;
- storage location;
- supplier lead time.
Without reliable data, Kanban quantities and routes can become guesswork.
Support point-of-use material
PFEP should help answer:
Where should this part be stored, in what quantity, and in what container so the operator can use it safely and efficiently?
That connects with 5S and work-cell design.
Too much material creates congestion.
Too little material creates shortages.
The goal is controlled availability.
Keep the data current
PFEP is not a one-time spreadsheet.
Material systems change.
New parts are introduced.
Usage changes.
Suppliers change.
Packaging changes.
The PFEP should have ownership and a defined update process.
PFEP and supermarkets
A supermarket pull system depends on controlled inventory locations and replenishment quantities.
PFEP can define:
- which parts belong in the supermarket;
- standard container quantity;
- number of containers;
- route frequency;
- point-of-use destination.
This helps convert material flow from firefighting into standard work.
Common mistakes
Building a database nobody maintains, including unnecessary fields, using inaccurate usage data, failing to connect PFEP to physical locations, and allowing local workarounds to bypass the defined system are common problems.
Practical sequence
- Define the material-flow scope.
- List every relevant part.
- collect current usage and supplier information.
- define container and packaging standards.
- define storage and point-of-use locations.
- define replenishment method and frequency.
- assign ownership.
- connect PFEP to Kanban and route design.
- verify the physical system.
- maintain the data as conditions change.
The practical lesson
PFEP turns material flow from tribal knowledge into a controlled system.
Good pull systems depend on good information about every part they are expected to replenish.