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Duration 14 hours
Course Outline
Introduction
- Historical context of Lean: The Toyota Production System
- Distinguishing Lean Manufacturing from Lean Distribution
Core Concepts of Lean Distribution
- Managing change and adaptation in distribution
- Enhancing distribution operations
- The foundational framework for Lean Distribution
- Addressing common distribution challenges
- Strategies for distribution optimization
- Transforming business processes
- Implementing ERP system transformations
Lean Distribution Methodology
- Developing Lean capabilities
- Establishing customer service policies
- Formulating buffer strategies
- Optimizing replenishment cycles
- Adopting the pull-based approach
Preparation for Lean Distribution
- Strategic planning for Lean transformation
- Conducting a comprehensive process inventory
- Calculating the comprehensive cost of fulfillment
- Setting KPIs tailored to client requirements
- Analyzing transactional details from receipt through to delivery
- Strategies for overcoming resistance to change
- Designing and preparing a pilot project
Essential Diagnostic Questions
- Applying the Five Whys technique
- Identifying probable causes: moving beyond symptoms to uncover root issues
- Utilizing cause and effect diagrams
Executing Lean Distribution
- Forming high-performing teams
- Measuring performance and making adjustments
- Systematic elimination of waste
- Implementing just-in-time delivery
- Minimizing unnecessary human effort
- Prioritizing safety and workplace cleanliness
Optimizing Inventory Flow
- Why improving isolated events is insufficient
- Connecting improvement activities through vision and planning
- Application of Value Stream Mapping (VSM)
Lean Tools for Warehouse Operations
- Pareto analysis – Identifying the most significant problems
- Cause and effect diagram – Determining the root causes of issues
- Stratification – Understanding data composition
- Check sheets – Measuring frequency of occurrence
- Histograms – Assessing overall variation
- Scatter charts – Analyzing relationships between variables
- Process control charts – Managing and controlling specific variations
Evaluating Lean Outcomes
- Using the Lean maturity matrix
- Monitoring and tracking performance metrics
- Benchmarking against industry peers
- Maintaining continuous monitoring and improvement cycles
Cultivating Lean Leadership
- Building a dedicated Lean leadership team
- Establishing a robust succession system
Complementary Methodologies
- Integrating Agile and Scrum practices
- Applying Six Sigma principles
Concluding Remarks
Requirements
- A commitment to developing talent, enhancing operational efficiency, and reducing waste in distribution and supply chain activities.
Target Audience
- Managers and specialists tasked with introducing Lean principles into distribution, logistics, and supply chain workflows
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
