2.5 A-Part Control Tower (Critical Parts Management)

The Pareto Principle dominates supply chain physics: 20% of the components create 80% of the risk. Treating a high-value FPGA with the same administrative passivity as a standard 10k resistor is professional negligence. The A-Part Control Tower is a dedicated operating model for this critical minority—the items that define the "Critical Path" and determine whether the factory runs or halts.

Defining the "Class A" Portfolio

You cannot micro-manage 5,000 line items. You must surgically identify the "Class A" population based on risk, not just price.

Selection Criteria (The Filter)

Any component meeting ONE of the following conditions is an A-Part:

1. Single Source: No approved alternate on the AVL. (Risk: Total Line Down).
2. Lead Time > 20 Weeks: Recovery from a mistake takes half a year.
3. High Spend (Top 20%): Inventory errors here destroy cash flow.
4. Allocated / Market Constraint: Industry-wide shortage (e.g., global MLCC crisis).

Pro-Tip: Tag these items explicitly in the ERP as "Planner Code: A". This allows for filtered reporting and prevents auto-ordering without human review.

Operational Logic: The Three-Stage Defense

For A-Parts, automation is secondary to human verification. Apply the "Three-Stage Procurement Logic" operationally.

Stage 1: Pre-PO Validation (The Setup)

• Action: Before the PO is cut, re-validate Lead Time and Price with the vendor.
• Logic: Do not trust the system data. Market conditions for Class A parts change weekly.
• Rule: No "touchless" POs for A-Parts. Every order requires a manual "Buyer Review" gate.

Stage 2: Mid-Cycle Confirmation (The Watch)

• Action: The "T-Minus" Check.
  • T-30 Days: Email vendor for "WIP Check" (Is the wafer started?).
  • T-14 Days: Confirm shipping slot.
• Logic: Silence is a threat. If you haven't heard from the vendor, assume the schedule has slipped.

Stage 3: Logistics Acceleration (The Landing)

• Action: Pre-clear customs. Verify correct HTS codes.
• Logic: Do not let a $50,000 shipment sit in a customs hold for 5 days because of a paperwork error.
• Trigger: If T-5 days and no tracking number $\rightarrow$ Escalate immediately.

The Control Tower Dashboard

Visual management is essential. Create a "Control Tower" view (Live Dashboard) that links material status directly to the Production Schedule.

Dashboard Structure:

Project	Build Date	Part Number	Status	Commit Date	Gap (Days)	Risk Level	Action Owner
P-204	Oct 15	FPGA-X7	CRITICAL	Oct 20	-5	Line Down	S. Director
P-204	Oct 15	Conn-USB	At Risk	Oct 14	+1	High	J. Doe
P-205	Nov 01	MCU-ARM	On Track	Oct 20	+10	Low	S. Smith

Market Signal Monitoring

For A-Parts, you must look outside the four walls of the factory. Monitor external signals to predict internal failures.

The Watch List:

1. Lead Time Trends: Is the OCM extending lead times globally? (Signal: Order now for next year).
2. Factory Output: Did a major fab have a fire/earthquake? (Signal: Immediate buffer buy).
3. Pricing Spikes: Are spot market prices rising? (Signal: Allocation is starting).

Decision Logic: The "Alternate Trigger"

• If Lead Time Trend is increasing + Vendor performance is degrading:
• Then Trigger Engineering Qualification for a second source before the shortage hits.
• Why: Qualifying a new MCU takes 12 weeks. If you wait until the line stops, you are too late.

Escalation Rules

A-Part issues bypass standard escalation ladders. They go straight to the top.

• Rule: Any negative slip (> 3 days) on an A-Part Commit Date must be reported to the Supply Chain Director within 4 hours.
• Constraint: "Waiting for email reply" is not a valid status for A-Parts. Pick up the phone.

Final Checklist

Control Point	Requirement	Critical Threshold
Identification	"Class A" Tag in ERP	100% Accuracy
PO Method	Manual Review (No Auto-PO)	Mandatory
Validation	WIP Check (T-30 Days)	Documented
Escalation	Director Notification	< 4 Hours from Slip
Alternates	Dual Source Strategy	Active Roadmap
Logistics	Premium Freight Authority	Pre-Approved