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Duration 14 hours
Course Outline
Introduction
- The Origins of Lean: The Toyota Production System
- Comparing Lean Manufacturing and Lean Distribution
Core Concepts of Lean Distribution
- Managing Lean change in distribution
- Enhancing distribution operations
- The structural framework for Lean Distribution
- Challenges in distribution
- Optimizing distribution processes
- Transforming business processes
- ERP transformation
Lean Distribution Methodology
- Building Lean capabilities
- Defining customer service policies
- Developing buffer strategies
- Managing replenishment cycles
- Implementing the pull approach
Preparing for Lean Distribution
- Planning the Lean transformation
- Assessing current processes
- Calculating the total cost of fulfillment
- Setting KPIs based on client requirements
- Analyzing transactional details from receipt to delivery
- Addressing resistance to change
- Designing a pilot project
Key Diagnostic Questions
- The Five Whys technique
- Identifying root causes rather than just symptoms
- Using cause and effect diagrams
Implementing Lean Distribution
- Forming effective teams
- Measuring and refining processes
- Removing waste
- Ensuring just-in-time delivery
- Reducing unnecessary human effort
- Emphasizing safety and cleanliness
Enhancing Inventory Flow
- Why improving individual events is insufficient
- Creating vision and plans to link improvement activities
- Applying Value Stream Mapping (VSM)
Lean Tools for Warehouse Operations
- Pareto analysis – identifying major problems
- Cause and effect diagrams – determining problem origins
- Stratification – understanding data composition
- Check sheets – tracking frequency of issues
- Histograms – observing overall variation
- Scatter charts – analyzing relationships between factors
- Process control charts – managing specific variations
Evaluating Lean Results
- Using the Lean maturity matrix
- Monitoring performance metrics
- Benchmarking against industry peers
- Ensuring continuous monitoring and improvement
Cultivating Lean Leadership
- Establishing a Lean leadership team
- Building a succession system
Complementary Methodologies
- Agile and Scrum
- Six Sigma
Conclusion
Requirements
- A commitment to developing people, 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
