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Duration 14 hours
Course Outline
Introduction
- The History of Lean: The Toyota Production System
- Distinguishing Lean Manufacturing from Lean Distribution
Core Concepts of Lean Distribution
- Lean change and its impact on distribution
- Enhancing distribution operations
- The foundational framework for Lean Distribution
- Addressing distribution challenges
- Optimizing distribution processes
- Transforming business processes
- Transforming ERP systems
Lean Distribution Methodology
- Developing Lean capabilities
- Defining customer service policies
- Formulating buffer strategies
- Managing replenishment cycles
- Adopting the pull approach
Preparing for Lean Distribution
- Planning a Lean transformation
- Conducting an inventory of processes
- Calculating the total cost of fulfillment
- Defining KPIs aligned with client needs
- Observing transactional-level details from receipt to delivery
- Overcoming resistance to change
- Preparing a pilot project
Key Questions to Consider
- Applying the Five Whys technique
- Identifying probable causes: looking beyond symptoms to uncover root causes
- Utilizing cause and effect diagrams
Implementing Lean Distribution
- Assembling effective teams
- Measuring performance and making adjustments
- Eliminating waste
- Implementing Just-in-time delivery
- Minimizing human effort
- Prioritizing safety and cleanliness
Optimizing Inventory Flow
- Why improving individual events is insufficient
- Providing vision and plans to connect improvement activities
- Value Stream Mapping (VSM)
Lean Tools for Warehouse Operations
- Pareto analysis – identifying the most significant problems
- Cause and effect diagrams – determining what is causing the problem
- Stratification – understanding how the data is composed
- Check sheets – measuring the frequency of occurrences
- Histograms – assessing overall variation
- Scatter charts – analyzing relationships between factors
- Process control charts – determining which variations to control and how
Evaluating Lean Outcomes
- Using the Lean maturity matrix
- Tracking performance metrics
- Benchmarking against industry peers
- Engaging in continuous monitoring and improvement
Cultivating Lean Leadership
- Building a Lean leadership team
- Establishing a succession system
Complementary Methodologies
- Agile and Scrum
- Six Sigma
Closing Remarks
Requirements
- A commitment to developing talent, enhancing efficiency, and eliminating waste in distribution and supply chain operations.
Target Audience
- Managers and professionals tasked with implementing lean principles in distribution, logistics, and supply chain operations
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
