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Lean Warehousing and Distribution Operations (2 Day Class)

Description:
This highly interactive two-day workshop is for people responsible for implementing lean principles in a distribution center operation.

The workshop combines lecture, group discussion, participative simulations, and group exercises to reveal the key steps for implementing lean principles in a traditional distribution operation. Topics include the development of a storage environment that enables a conventional distribution facility with improved efficiency, quality, safety, and space utilization.

In the course of the workshop, we create an experiential learning environment which allows the participants to understand – through the series of rapid PDCA cycles – the phases and steps to transform your operational processes in order to improve customer service, reduce costs, and provide a problem-solving environment for continuous improvement. Progressing through our three-round simulation, you will identify changes, implement them, and measure the impact of applying lean tools and principles to distribution processes.

Round 1: reflects a conventional distribution center and its impact on customers, associates and management
Round 2: reflects a distribution center after a Lean benchmarking trip taken by management
Round 3: will reflect an operation after lean storage techniques and processes have been implemented

Both operating systems are evaluated and compared for on-time deliveries, lead time, quality, efficiency, distribution center space and equipment utilization, and cost per shipping line.

You will learn the key steps for implementing lean principles and converting a traditional warehouse operation. Hands-on participation in a simulation will teach you how to apply the tools so you can repeat the application in your environment. Companies applying these principles, components, steps, and tools have experienced operational improvements in reduced internal damage and injuries along with improved storage and operational efficiencies of 15% to 30%.

Course Outline:
Day One

  • Lean Warehouse Overview
  • Simulation/Round 1: Traditional Operation
  • Simulation/Round 2: Operation after Lean Benchmarking
  • Lean Implementation Frameworks
  • Lean Storage
  • Group Exercise

Day Two

  • Lean Implementation Framework
  • Process Implementation: Phases 1-3
    • Standardize/Stabilize Current State
    • Future State Standardized Work
    • Group exercise
    • Future State Operational Design
  • Process Implementation Phases 4-5
    • Synchronized Operations
    • Exercises
    • Stabilize/Improve Processes
  • Simulation/Round 3: Lean Warehouse Operation
  • Summary

Who Should Attend:
All levels of management from Vice-President to Supervisor, Change Agents, Professional Staff, and Hourly Associates from organizations at any stage of a lean journey.

Instructors:
Manny Cantone

Prior to joining Lean Quest, Manny worked for 7 years in the North American Parts Operations Division of Toyota. While with Toyota he was responsible for operations and facility design, storage management and training, Total Quality Management (TQM) and Toyota Production System (TPS) training, associate development, and implementation of JIT principles and Lean methods throughout the supply chain.

Alan Noss

Alan received his introduction to lean when he worked for 13 years in the Service Parts Logistics Division of Toyota. During his tenure, he has been responsible for on-going training, development, and implementation of Lean methods throughout the supply chain. He implemented the first regional rollout of JIT deliveries to the dealership level and helped design and develop the operational procedures for a new Toyota distribution center using an automated warehouse control system and integrating material handling equipment into operational processes. Alan received top honors at 1997 North American Kaizen Conference and was selected to represent North America at 1998 Kaizen World Cup in Japan. Alan currently aids companies implementing lean through Lean Quest.

Tom Shuker

Tom is a 30-year veteran in various manufacturing environments within General Motors Corporation. Tom has also spent two-years at New United Motors Manufacturing Inc. (NUMMI), the GM-Toyota joint venture, working within the Toyota Manufacturing System and performing lean assessments of Toyota facilities in Kentucky and Japan. Tom has co-authored two books on Lean, Value Stream Management and Value Stream Management for the Lean Office, both published through Productivity Press, Inc. Tom is also a co-author of Mapping to See – A Value-Stream Improvement Kit for Office and Service, published by the Lean Enterprise Institute. He has a Bachelor of Science degree from Michigan State University, and an MBA from Western Michigan University. He currently aids companies implementing lean through an investment group that purchases small manufacturing firms and helps turn them around and as a member of the consulting group Lean Transformations Group.

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.

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:
Price: $1,600.00 ($1,400.00 if the participant is taking 2 or more workshops at one location)
Price includes all participant materials, breakfast, lunch and snacks each day.
Locations and Dates for Lean Warehousing and Distribution Operations
April 6, 2010  
Hyatt Regency San Antonio
San Antonio, TX
Instructor(s): Dave Graham
Schedule
Day 1: 8:00 AM to 4:00 PM
Day 2: 8:00 AM to 4:00 PM
Hotel Discount Available

We encourage you to make hotel accommodations early.

Cancelation Policy
Our educational events are designed to cater to a limited number of participants. If you must cancel a registration, refunds can be issued until the set refund date (20 business days prior to the start of the workshop series). After that date, no refunds will be processed. If you cancel after that date, you will be given a credit for the full amount paid, good for one year (for either yourself or someone else in your organization). You are responsible for contacting LEI to facilitate receiving the credit. To cancel please call LEI at (617) 871-2900.
Hyatt Regency San Antonio
210-222-1234

Discounted Room Rate: $179.00 USD
Room Rate Expires: March 1, 2010
To receive the special room rate, you must call the hotel directly at the number given above, before the specified expiration date, and ask for the Lean Enterprise Institute room block.