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Duration 14 hours
Course Outline
Introduction
- Origins of Lean: The Toyota Production System
- Distinguishing Lean Manufacturing from Lean Distribution
Core Concepts of Lean Distribution
- Managing change in distribution
- Enhancing distribution operations
- Establishing the Lean Distribution framework
- Addressing distribution-specific challenges
- Optimizing distribution processes
- Transforming business processes
- ERP system transformation
Lean Distribution Methodology
- Developing Lean capabilities
- Formulating customer service policies
- Strategizing buffers
- Designing replenishment cycles
- Implementing the pull approach
Preparing for Lean Distribution
- Planning the Lean transformation
- Assessing current processes
- Calculating the comprehensive cost of fulfillment
- Setting KPIs aligned with client requirements
- Analyzing transactional details from receipt to delivery
- Mitigating resistance to change
- Designing a pilot project
Key Diagnostic Questions
- The Five Whys technique
- Identifying probable causes by looking beyond symptoms to uncover root issues
- Utilizing cause and effect diagrams
Implementing Lean Distribution
- Forming cross-functional teams
- Measuring and refining processes
- Removing waste
- Implementing just-in-time delivery
- Minimizing manual effort
- Prioritizing safety and cleanliness
Optimizing Inventory Flow
- The insufficiency of improving individual events
- Providing vision and planning to link improvement efforts
- Value Stream Mapping (VSM)
Lean Tools for Warehousing
- Pareto analysis – identifying significant problems
- Cause and effect diagrams – determining problem drivers
- Stratification – understanding data composition
- Check sheets – measuring frequency of occurrence
- Histograms – assessing overall variation
- Scatter charts – analyzing relationships between factors
- Process control charts – managing critical variations
Evaluating Lean Results
- Using the Lean maturity matrix
- Monitoring performance
- Benchmarking against industry peers
- Continuous monitoring and enhancement
Cultivating Lean Leadership
- Building a Lean leadership team
- Establishing a succession system
Complementary Methodologies
- Agile and Scrum
- Six Sigma
Conclusion
Requirements
- A commitment to developing personnel, enhancing efficiency, and eliminating waste within distribution and supply chain operations.
Target Audience
- Managers and professionals tasked with implementing lean principles in distribution, logistics, and supply chain functions
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
