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Duration 14 hours
Course Outline
Introduction
- The Origins of Lean: The Toyota Production System
- Distinguishing Between Lean Manufacturing and Lean Distribution
Core Concepts of Lean Distribution
- Managing change within distribution networks
- Enhancing distribution operations
- The underlying framework for Lean Distribution
- Common challenges in distribution
- Optimizing distribution processes
- Transforming business processes
- ERP system transformation
Lean Distribution Methodology
- Developing Lean capabilities
- Establishing customer service policies
- Implementing buffer strategies
- Optimizing replenishment cycles
- Adopting the pull-based approach
Readying for Lean Distribution
- Strategizing the Lean transformation
- Conducting a process inventory
- Calculating the total cost of fulfillment
- Defining KPIs based on client requirements
- Analyzing transactional details from receipt to final delivery
- Addressing resistance to change
- Designing a pilot project
Essential Diagnostic Questions
- Applying the Five Whys technique
- Identifying root causes rather than just symptoms
- Utilizing cause and effect diagrams
Executing Lean Distribution
- Forming cross-functional teams
- Measuring performance and making adjustments
- Systematically eliminating waste
- Implementing just-in-time delivery
- Reducing unnecessary human effort
- Prioritizing safety and workplace cleanliness
Enhancing Inventory Flow
- Going beyond isolated event improvements
- Creating a vision to link various improvement activities
- Conducting Value Stream Mapping (VSM)
Lean Tools for Warehouse Management
- Pareto analysis – identifying the most significant issues
- Cause and effect diagrams – determining what triggers problems
- Stratification – analyzing data composition
- Check sheets – tracking frequency of occurrence
- Histograms – assessing overall variation
- Scatter charts – understanding relationships between variables
- Process control charts – determining which variations require control and how
Evaluating Lean Outcomes
- Using the Lean maturity matrix
- Monitoring performance metrics
- Benchmarking against industry peers
- Maintaining continuous monitoring and improvement
Cultivating Lean Leadership
- Building a dedicated Lean leadership team
- Establishing a succession planning system
Supporting Methodologies
- Integrating Agile and Scrum
- Applying Six Sigma
Conclusion
Requirements
- A commitment to developing team capabilities, enhancing operational efficiency, and eliminating waste in distribution and supply chain processes.
Target Audience
- Managers and professionals tasked with implementing Lean principles within 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
