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Duration 14 hours
Course Outline
Introduction
- The history of Lean: The Toyota Production System
- Distinguishing between Lean Manufacturing and Lean Distribution
Core Concepts of Lean Distribution
- Lean change management in distribution
- Enhancing distribution operations
- The framework for Lean Distribution
- Common distribution challenges
- Optimizing distribution processes
- Transforming business processes
- ERP system transformation
Lean Distribution Methodology
- Developing Lean capabilities
- Customer service policies
- Buffer strategies
- Replenishment cycles
- Implementing the pull approach
Preparing for Lean Distribution
- Planning a Lean transformation
- Conducting a process inventory
- Calculating the total cost of fulfillment
- Defining KPIs tailored to the client
- Observing transactional details from receipt to delivery
- Overcoming organizational resistance
- Preparing a pilot project
Essential Diagnostic Questions
- Applying the Five Whys
- Identifying probable causes—moving beyond symptoms to uncover root issues
- Utilizing cause-and-effect diagrams
Implementing Lean Distribution
- Assembling cross-functional teams
- Measuring performance and making adjustments
- Eliminating waste
- Implementing just-in-time delivery
- Minimizing unnecessary human effort
- Prioritizing safety and cleanliness
Enhancing Inventory Flow
- Why improving isolated events is insufficient
- Providing vision and planning to link improvement activities
- Value Stream Mapping (VSM)
Lean Tools for Warehousing
- Pareto analysis – identifying the major issues
- Cause-and-effect diagram – determining the root causes
- Stratification – analyzing data composition
- Check sheets – measuring frequency of occurrence
- Histograms – assessing overall variation
- Scatter charts – evaluating relationships between factors
- Process control charts – managing specific variations
Evaluating Lean Results
- The Lean maturity matrix
- Performance tracking
- Benchmarking against industry peers
- Continuous monitoring and refinement
Developing Lean Leaders
- Establishing a Lean leadership team
- Creating a succession planning 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 processes.
Target Audience
- Managers and professionals tasked with applying Lean principles to 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
