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Duration 14 hours (2 days)
Course Outline
Introduction
- The Origins of Lean: The Toyota Production System
- Comparing Lean Manufacturing and Lean Distribution
Foundations of Lean Distribution
- Lean change management in distribution
- Enhancing distribution operations
- The structural framework for Lean Distribution
- Challenges specific to distribution
- Optimizing distribution processes
- Transforming business processes
- ERP system transformation
Lean Distribution Methodology
- Core Lean capabilities
- Customer service policies
- Buffer management strategies
- Replenishment cycles
- The pull-based approach
Readiness for Lean Distribution
- Planning the Lean transformation journey
- Conducting a process inventory
- Calculating the total cost of fulfillment
- Defining KPIs in alignment with client needs
- Analyzing transactional details from receipt to delivery
- Addressing resistance to change
- Designing a pilot project
Diagnostic Questions
- The Five Whys technique
- Identifying root causes beyond surface-level symptoms
- Utilizing cause and effect diagrams
Executing Lean Distribution
- Forming effective teams
- Measuring outcomes and making adjustments
- Eliminating non-value-added activities
- Implementing just-in-time delivery
- Reducing unnecessary human effort
- Prioritizing safety and cleanliness
Optimizing Inventory Flow
- Moving beyond isolated event improvements
- Providing a strategic vision to link improvement initiatives
- Value Stream Mapping (VSM)
Essential Lean Tools for Warehousing
- Pareto analysis – identifying major issues
- Cause and effect diagrams – determining problem origins
- Stratification – understanding data composition
- Check sheets – measuring frequency of occurrence
- Histograms – analyzing overall variation
- Scatter charts – exploring factor relationships
- Process control charts – managing specific variations
Evaluating Lean Outcomes
- The Lean maturity matrix
- Performance tracking
- Benchmarking against industry peers
- Ongoing monitoring and refinement
Cultivating Lean Leadership
- Building a Lean leadership team
- Establishing a succession planning system
Complementary Methodologies
- Agile and Scrum frameworks
- Six Sigma
Conclusion
Requirements
- A commitment to developing talent, enhancing efficiency, and reducing waste within distribution and supply chain processes.
Intended Audience
- Managers and professionals tasked with implementing lean principles in distribution, logistics, and supply chain environments
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