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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

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Price per participant

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