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Course Outline
Introduction
- The legacy of Lean: The Toyota Production System
- Distinguishing Lean Manufacturing from Lean Distribution
Core Concepts of Lean Distribution
- Facilitating Lean change in distribution
- Enhancing distribution operations
- The structural framework for Lean Distribution
- Common challenges in distribution
- Optimising distribution processes
- Transforming business processes
- ERP system transformation
Lean Distribution Methodology
- Developing Lean capabilities
- Defining customer service policies
- Implementing buffer strategies
- Managing replenishment cycles
- Applying the pull approach
Preparing for Lean Distribution
- Planning the Lean transformation
- Conducting a process inventory
- Calculating the total cost of fulfilment
- Setting KPIs aligned with client requirements
- Monitoring transactional details from receipt to delivery
- Addressing resistance to change
- Designing a pilot project
Diagnostic Questions
- The Five Whys technique
- Identifying probable causes by looking beyond symptoms to root causes
- Utilising cause-and-effect diagrams
Implementing Lean Distribution
- Forming cross-functional teams
- Measuring performance and making adjustments
- Eliminating waste
- Implementing just-in-time delivery
- Reducing manual effort
- Prioritising safety and workplace cleanliness
Optimising Inventory Flow
- Recognising that improving isolated events is insufficient
- Establishing vision and plans to link improvement initiatives
- Value Stream Mapping (VSM)
Lean Tools for Warehousing
- Pareto analysis – identifying major issues
- Cause-and-effect diagrams – determining the root cause
- Stratification – understanding data composition
- Check sheets – measuring frequency of occurrence
- Histograms – analysing overall variation
- Scatter charts – exploring relationships between variables
- Process control charts – determining which variations to manage and how
Evaluating Lean Outcomes
- Using the Lean maturity matrix
- Tracking performance metrics
- Benchmarking against industry peers
- Maintaining continuous monitoring and improvement
Cultivating Lean Leadership
- Building a Lean leadership team
- Establishing a succession system
Complementary Methodologies
- Agile and Scrum frameworks
- Six Sigma
Conclusion
Requirements
- A commitment to developing personnel, enhancing efficiency, and minimising waste within distribution and supply chain operations.
Target Audience
- Managers and professionals tasked with implementing Lean principles across distribution, logistics, and supply chain functions
14 Hours
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