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Duration 14 hours
Course Outline
Introduction
- The evolution of Lean: Origins in the Toyota Production System
- Distinguishing between Lean Manufacturing and Lean Distribution
Core Concepts of Lean Distribution
- Managing change within distribution networks
- Enhancing distribution operational efficiency
- The foundational framework for Lean Distribution
- Addressing common distribution challenges
- Strategies for distribution optimization
- Transforming business processes
- ERP system transformation
Lean Distribution Methodology
- Developing Lean capabilities
- Formulating customer service policies
- Implementing buffer strategies
- Optimizing replenishment cycles
- Applying the pull-based approach
Preparation for Lean Distribution
- Planning a comprehensive Lean transformation
- Conducting a thorough process inventory
- Calculating the comprehensive cost of fulfillment
- Aligning KPIs with client expectations
- Analyzing transactional details from receipt through to delivery
- Addressing and mitigating resistance
- Designing a pilot project
Diagnostic Questions
- Applying the Five Whys technique
- Identifying root causes: Moving beyond symptoms to uncover underlying issues
- Utilizing cause and effect diagrams
Executing Lean Distribution
- Building high-performing implementation teams
- Measuring outcomes and making adjustments
- Systematically eliminating waste
- Implementing Just-in-time delivery principles
- Reducing unnecessary human effort
- Prioritizing safety and workplace cleanliness
Enhancing Inventory Flow
- Why improving isolated events is insufficient
- Creating vision and plans to link improvement initiatives
- Value Stream Mapping (VSM)
Lean Tools for Warehouse Operations
- Pareto analysis – Identifying the most significant issues
- Cause and effect diagram – Determining the root causes of problems
- Stratification – Understanding data composition
- Check sheets – Measuring frequency of occurrence
- Histograms – Analyzing overall variation
- Scatter charts – Exploring relationships between variables
- Process control charts – Managing and controlling variation
Evaluating Lean Outcomes
- Utilizing the Lean maturity matrix
- Monitoring performance metrics
- Benchmarking against industry peers
- Maintaining continuous monitoring and improvement cycles
Cultivating Lean Leadership
- Forming a dedicated Lean leadership team
- Establishing a succession planning system
Complementary Frameworks
- Integration with Agile and Scrum
- Integration with Six Sigma
Conclusion
Requirements
- A commitment to enhancing team capabilities, boosting operational efficiency, and eradicating waste within distribution and supply chain workflows.
Target Audience
- Managers and professionals tasked with adopting lean principles in distribution, logistics, and supply chain management
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
