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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

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