Introduction
History of Lean: The Toyota Production System
Lean Manufacturing vs Lean Distribution
Lean Distribution Concepts
Lean change and distribution
Distribution operations improvement
The framework for Lean Distribution
Distribution challenges
Distribution optimization
Business process transformation
ERP transformation
Lean Distribution Methodology
Lean capabilities
Customer service policy
Buffer strategy
Replenishment cycles
The pull approach
Preparing for Lean Distribution
Planning a Lean transformation
Taking inventory of the process
Calculating the total cost of fulfillment
Defining KPIs according to the client
Observing transactional-level details from receipt to delivery
Overcoming resistance
Preparing a pilot project
Questions to Ask
The Five Whys
Identifying probable cause - beyond symptoms and uncovering root causes of problems
The cause and effect diagram
Implementing Lean Distribution
Assembling the teams
Measuring and adjusting
Eliminating waste
Just-in-time delivery
Minimizing human effort
Prioritizing safety and cleanliness
Improving the Flow of Inventory
Improving events is not enough
Providing vision and plans to connect improvement activities
Value Stream Mapping (VSM)
Lean Tools for the Warehouse
Pareto analysis – what are the big problems?
Cause and effect diagram – what’s causing the problem?
Stratification – how is the data made up?
Check sheet – how often does it occur?
Histograms – what is the overall variation?
Scatter charts – what are the relationships between the factors?
Process control chart – which variations to control and how?
Assessing the Results of Lean
Lean maturity matrix
Tracking performance
Benchmarking against other companies
Continuous monitoring and improvement
Developing Lean Leaders
Creating a Lean leadership team
Creating a succession system
Complimentary Methodologies
Agile and Scrum
Six Sigma
Closing Remarks
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