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Lean Warehousing: Introduction (1 Day Class)

Experience Requirements and Suggested Reading:
This workshop assumes you are familiar with basic lean terms and concepts as described in Lean Thinking by Jim Womack and Dan Jones.  To maximize your learning experience, we suggest that you should have some experience with value-stream mapping and the development of standardized work in a manufacturing or a warehousing setting.

This course is for individuals in warehouse operations that have not yet started a lean implementation and are just beginning to consider implementing lean and would like to understand more about a lean implementation approach and how to get started with creating an environment for a successful lean implementation.

You'll learn how to create the right preconditions for the transformation by analyzing current volumes, performance, capacity and workforce allocation at a detailed level. You'll also learn how to create the all-important standardized work for a lean warehouse by applying the lean principles of 5S, Process Flows, Standard Work Instructions, and Job Instructions.

Exercises, real-world examples, and hands-on simulations will show you how to deploy the basic concepts and tools of a lean warehouse. Applying these fundamental elements can improve performance by 5% to 10%, reduce overtime, and improve on-time delivery to customers. You’ll also learn a process for identifying opportunities for further performance improvements through improved workforce allocation, 5S, and standardized work.

Course Outline:

  • Lean Warehouse Foundations Overview
  • Knowing your business
  • Volume overview
  • 5 S overview and exercise
  • Standardization Overview and exercise
  • Simulation
  • Job instruction overview
  • Implementing 5S improvements
  • Performance & Resource Allocation
  • Continuous Improvement overview - PDCA
  • Simulation continued
  • Continuous improvement exercise

Who Should Attend:
Those who would benefit from attending this workshop include:

  • Lean Managers
  • Supervisors
  • Operations Managers
  • Distribution Center Managers
  • Director of Operations
  • Union Leadership
Dave Graham Dave Graham
David’s lean knowledge came from 17 years with the North American Parts Operations Division of Toyota, where he applied lean concepts to the launch of a distribution center, the company’s largest, supplying all North American sourced parts. He also was responsible for teaching just-in-time concepts to North American distributors and dealers. His Toyota responsibilities included creation of the Toyota Consulting Group to help the company’s North American suppliers, distributors, and dealers implement lean methods. While at Toyota, he applied pull and flow at the company’s second-largest distribution center and deployed just-in-time principles to dealerships in two regions of the U.S. He currently aids companies implementing lean through Lean Quest.
Guy Moniz Guy Moniz

With over 16 years of Lean implementation & management experience, Guy’s career started & flourished with the Toyota Motor Sales, USA – Parts Distribution & Logistics Division planning, directing, and supporting Toyota Production System (TPS) & continuous improvement activities within the organization’s San Francisco Area Parts Distribution Center. Ranging across a spectrum of operational categories including process development, inventory control, supply procurement, storage, transportation, customer service, occupational safety & health, and others, Guy has led various teams in well over 100 Kaikaku improvement projects & supported thousands of Teian-type incremental improvement efforts. One of a select few employees to win the coveted Toyota Global Kaizen Marathon, Guy actively spread his knowledge across the US Distribution Network, formally & informally engaged throughout his tenure in both internal as well as yokotan (cross-organizational) training efforts. Seeking new career challenges, Guy later brought his TPS knowledge to a privately labeled pharmaceutical-based manufacturer in the San Francisco Bay Area where he acted as Director of Operations for four years. Prior to joining Lean Quest in 2006, Guy was aggressively involved in the strategic planning & tactical implementation of Menlo Worldwide’s global lean culture transformation.

Workshop Suggestions:
To maximize your learning experience we recommend that prior to attending this program you take following workshops or have a good understanding of the concepts presented within them.
Suggested Reading for this Workshop:
Locations and Dates for Lean Warehousing: Introduction

No offerings of this workshop are scheduled at this time. Please check back again soon.

Price: $800.00 ($700.00 if the participant is taking 2 or more workshops at one location)
Price includes all participant materials, breakfast, lunch and snacks each day

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Cancelation Policy
Our workshops are designed to cater to a limited number of participants.  If you must cancel a workshop registration, you will be given a full refund up to four weeks before the workshop. A cancelation occuring within four weeks of the workshop will be subjected to a $350 cancelation fee.  Substitutions may be made at any time prior to the start of the workshop. To cancel a workshop registration, please call LEI at (617) 871-2900.