Definition
Tools for analysing the steps of the spare parts production process, which are used to shift from bulk sector layout to mobile value streams.
In detail
Part Quantity/Process Route (PQPR) is a tool for analyzing part production process steps, used to shift from batch-style departmental layout to flow-oriented value streams. By tallying demand volume and process routes for each product, it identifies product families and provides the basis for cell layout. It addresses the question of "how to organize high-mix, low-volume production into efficient Flow," and differs from Value Stream Mapping (VSM): VSM focuses on the overall process, while PQPR focuses on product family segmentation. Typical outputs: product-process matrix, product family classification, equipment requirement list.
Example in practice
A machinery factory produces 20 types of parts. Through PQPR analysis, they found that 10 types had similar process routes and high demand, so they grouped them into one product family and designed a U-shaped cell for production. The remaining small-batch parts stayed in a functional layout. After implementation, changeover time was reduced by 50% and work-in-process inventory decreased.