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Duration 14 hours (2 days)
Course Outline
Introduction
- The origins of Lean: The Toyota Production System
- Differences between Lean Manufacturing and Lean Distribution
Core Lean Distribution Concepts
- Managing change within distribution
- Enhancing distribution operations
- The structural framework for Lean Distribution
- Common challenges in distribution
- Strategies for distribution optimization
- Transforming business processes
- ERP system transformation
Lean Distribution Methodology
- Developing Lean capabilities
- Formulating customer service policies
- Implementing buffer strategies
- Optimizing replenishment cycles
- Adopting the pull approach
Preparation for Lean Distribution
- Planning the Lean transformation
- Auditing current processes
- Calculating the comprehensive cost of fulfillment
- Defining KPIs based on client needs
- Analyzing transactional details from receipt through delivery
- Addressing resistance to change
- Designing a pilot project
Key Questions to Investigate
- Applying the Five Whys technique
- Identifying probable causes—moving beyond symptoms to uncover root problems
- Utilizing cause and effect diagrams
Implementation of Lean Distribution
- Building effective teams
- Monitoring metrics and making adjustments
- Removing non-value-adding steps
- Implementing just-in-time delivery
- Reducing unnecessary manual effort
- Prioritizing safety and workplace cleanliness
Enhancing Inventory Flow
- Why improving isolated events is insufficient
- Providing vision and planning to link improvement efforts
- Applying Value Stream Mapping (VSM)
Lean Tools for Warehouse Management
- Pareto analysis – identifying major issues
- Cause and effect diagrams – determining the source of problems
- Stratification – analyzing data composition
- Check sheets – tracking frequency of occurrence
- Histograms – understanding overall variation
- Scatter charts – analyzing relationships between factors
- Process control charts – identifying which variations to manage and how
Evaluating Lean Outcomes
- Using the Lean maturity matrix
- Monitoring performance indicators
- Benchmarking against industry peers
- Maintaining continuous monitoring and improvement
Cultivating Lean Leadership
- Establishing a Lean leadership team
- Developing succession planning systems
Complementary Methodologies
- Agile and Scrum frameworks
- Six Sigma practices
Conclusion
Requirements
- A commitment to developing talent, enhancing efficiency, and eliminating waste in distribution and supply chain operations.
Target Audience
- Managers and professionals tasked with applying 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