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Course Outline
Introduction
- History of Lean: The Toyota Production System
- Lean Manufacturing vs. Lean Distribution
Lean Distribution Concepts
- Lean change and distribution
- Improving distribution operations
- The framework for Lean Distribution
- Distribution challenges
- Distribution optimization
- Business process transformation
- ERP transformation
Lean Distribution Methodology
- Lean capabilities
- Customer service policy
- Buffer strategy
- Replenishment cycles
- The pull approach
Preparing for Lean Distribution
- Planning a Lean transformation
- Conducting a process inventory
- Calculating the total cost of fulfillment
- Defining KPIs according to client requirements
- Observing transactional-level details from receipt to delivery
- Overcoming resistance
- Preparing a pilot project
Questions to Ask
- The Five Whys
- Identifying probable causes – moving beyond symptoms to uncover root causes of problems
- The cause and effect diagram
Implementing Lean Distribution
- Assembling the teams
- Measuring and adjusting
- Eliminating waste
- Just-in-time delivery
- Minimizing human effort
- Prioritizing safety and cleanliness
Improving the Flow of Inventory
- Improvement events are not enough
- Providing vision and plans to connect improvement activities
- Value Stream Mapping (VSM)
Lean Tools for the Warehouse
- Pareto analysis – identifying the major problems
- Cause and effect diagram – determining what is causing the problem
- Stratification – understanding how data is composed
- Check sheet – determining frequency of occurrence
- Histograms – assessing overall variation
- Scatter charts – exploring relationships between factors
- Process control chart – identifying variations to control and how to control them
Assessing the Results of Lean
- Lean maturity matrix
- Tracking performance
- Benchmarking against other companies
- Continuous monitoring and improvement
Developing Lean Leaders
- Creating a Lean leadership team
- Creating a succession system
Complementary Methodologies
- Agile and Scrum
- Six Sigma
Closing Remarks
Requirements
- A strong desire to develop personnel, enhance efficiency, and eliminate waste in distribution and supply chain operations.
Audience
- Managers and professionals tasked with implementing Lean principles in distribution, logistics, and supply chain operations.
14 Hours
Testimonials (2)
Learning the basic meaning of lean and what steps are used to become lean.
Taggart Desmet - Orica Canada
Course - Lean Distribution: Implementing Lean in Distribution, Logistics, and Supply Chain Operations
I liked the small group setting