Course Outline

Introduction

  • History of Lean: The Toyota Production System
  • Lean Manufacturing vs. Lean Distribution

Lean Distribution Concepts

  • Change management in distribution
  • Improving distribution operations
  • The framework for Lean Distribution
  • Distribution challenges and solutions
  • Optimizing distribution processes
  • Business process transformation for government
  • ERP system transformation

Lean Distribution Methodology

  • Developing Lean capabilities
  • Formulating customer service policies
  • Implementing buffer strategies
  • Optimizing replenishment cycles
  • Adopting the pull approach

Preparing for Lean Distribution

  • Planning a Lean transformation initiative
  • Evaluating existing processes
  • Calculating the total cost of fulfillment
  • Defining KPIs aligned with client needs
  • Observing transactional details from receipt to delivery
  • Addressing resistance to change
  • Designing a pilot project

Questions to Ask

  • The Five Whys technique
  • Identifying root causes beyond surface-level symptoms
  • Using cause and effect diagrams

Implementing Lean Distribution

  • Forming implementation teams
  • Measuring performance and making adjustments
  • Eliminating waste in processes
  • Implementing just-in-time delivery systems
  • Reducing human effort through automation
  • Prioritizing safety and maintaining a clean environment

Improving the Flow of Inventory

  • Moving beyond isolated improvements
  • Creating vision and strategic plans to link improvement activities
  • Utilizing Value Stream Mapping (VSM)

Lean Tools for the Warehouse

  • Pareto analysis – identifying significant issues
  • Cause and effect diagram – pinpointing problem sources
  • Stratification – analyzing data composition
  • Check sheet – tracking frequency of occurrences
  • Histograms – assessing overall variability
  • Scatter charts – understanding factor relationships
  • Process control chart – managing and controlling variations

Assessing the Results of Lean

  • Using a Lean maturity matrix
  • Tracking performance metrics
  • Benchmarking against industry peers
  • Maintaining continuous monitoring and improvement efforts

Developing Lean Leaders

  • Building a Lean leadership team
  • Establishing a succession plan for leadership roles

Complimentary Methodologies

  • Agile and Scrum methodologies
  • Six Sigma techniques

Closing Remarks

Requirements

  • An aspiration to cultivate personnel, enhance efficiency, and reduce waste in distribution and supply chain operations for government.

Audience

  • Managers and professionals tasked with implementing lean principles in distribution, logistics, and supply chain operations for government.
 14 Hours

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