Course Details
Course Outline
5 days course
Introduction
- History of Lean: The Toyota Production System
- Lean Manufacturing vs Lean Distribution
Lean Distribution Concepts
- Lean change and distribution
- Distribution operations improvement
- The framework for Lean Distribution
- Distribution challenges
- Distribution optimization
- Business process transformation
- ERP transformation
Lean Distribution Methodology
- Lean capabilities
- Customer service policy
- Buffer strategy
- Replenishment cycles
- The pull approach
Preparing for Lean Distribution
- Planning a Lean transformation
- Taking inventory of the process
- Calculating the total cost of fulfillment
- Defining KPIs according to the client
- Observing transactional-level details from receipt to delivery
- Overcoming resistance
- Preparing a pilot project
Implementing Lean Distribution
- Assembling the teams
- Measuring and adjusting
- Eliminating waste
- Just-in-time delivery
- Minimizing human effort
- Prioritizing safety and cleanliness
Improving the Flow of Inventory
- Improving events is not enough
- Providing vision and plans to connect improvement activities
- Value Stream Mapping (VSM)
Lean Tools for the Warehouse
- Pareto analysis – what are the big problems?
- Cause and effect diagram – what’s causing the problem?
- Stratification – how is the data made up?
- Check sheet – how often does it occur?
- Histograms – what is the overall variation?
- Scatter charts – what are the relationships between the factors?
- Process control chart – which variations to control and how?
Assessing the Results of Lean
- Lean maturity matrix
- Tracking performance
- Benchmarking against other companies
- Continuous monitoring and improvement
Developing Lean Leaders
- Creating a Lean leadership team
- Creating a succession system
Complimentary Methodologies
- Agile and Scrum
- Six Sigma
