Learning Objectives:

Using an interactive and collaborative lean fulfillment steam simulation, students will learn how to:

• Value-Stream Map the extended enterprise
• Calculate and make decisions based on "total cost of fulfillment" for the entire supply chain
• Plan, calculate, and implement pull systems to drive material replenishment
• Break down cross functional barriers for effective supply stream collaboration
• Implement logistics concepts of increased delivery frequency, lot size reduction, and leveled flow

Workshop Description:

Lean is commonly misunderstood as a manufacturing application without much regard to supply chain and logistics. A lean organization is focused on adding value to the customer, problem solving, continuous improvement, and learning- characteristics necessary for all business functions. Thus, connecting lean to the entire supply chain network is required in a complete lean enterprise.

Modeled after the Shingo- award winning workbook Building a Lean Fulfillment Stream, this dynamic and highly interactive workshop teaches how to apply lean to the supply chain and logistics function.

The workshop highlights the critical elements and "must know" concepts of lean as they apply to the supply chain and logistics. It also provides you with the tools necessary to solve problems, eliminate waste, decrease inventory and lead time to help you improve processes and create level flow, thus ultimately decreasing the total cost of fulfillment.

Case Study: Lean Supply Chain:

• LeanCor Operations Center: Learn about lean operations being used in inbound logistics engineering, transportation management, and material materials management. See firsthand how lean principles and best practices are applied to the logistics and supply chain processes.
• LeanCor Lean Fulfillment Center:Learn about a lean warehouse in operation. Warehousing is often plagued with processes that are abundant in waste - from material receiving to pick and pack to shipping operations. Flow of inventory, disciplined processes, and visual management are cornerstones of effective warehousing operations. Understand how lean principles reduce waste in warehousing operations.

Key Concepts- Total Cost of Fulfillment and Customer Collaboration:

Is anyone in your organization trying to calculate and minimize total cost of fulfillment for the entire supply chain? The answer is likely "no." Embracing the total cost of fulfillment changes the way managers think, with major benefits for all the firms along the supply chain. Once managers adopt the goal of minimizing the total cost of fulfillment, collaboration across functions and firms becomes an obvious necessity. This goal requires a joint examination of the entire supply chain to determine total costs as the chain currently functions. And it requires a joint effort to envision a better supply chain that can benefit all of the firms involved.

Use the Building a Lean Supply Chain workshop to discover how lean creates a platform for providing maximum value to your customer, and how your organization can gain a competitive edge in today's ever evolving workforce.

 Benefits:

By applying the concepts and principles learned in this workshop, you will be able to:

• Improve supplier performance and accountability
• Improve customer satisfaction and customer relationships
• Drive lean supply-stream management and lean logistics through your organization
• Reduce the total cost of fulfillment through the reduction of inventory, space, lead time, logistics costs, and increased fill rates.

Course Outline:

Through instruction, discussion, small group activities, case study work, and interactive games, topics in this workshop will include:

Day 1:

• Lean Fulfillment Stream as a Process
• Lean Fulfillment Stream Principles
• Total Cost of Fulfillment
• Case Studies: End to End Improvement & Network Design 

Day 2 (Morning)

Lean Fulfillment Stream Simulation

• Decision 1: Customer Management - Sku Stratification
• Decision 2: Outbound Logistics - Network Design
• Decision 3: Shipping, Receiving and Trailer-Yard Management - Staffing
• Decision 4: Materials and Parts Ordering - Kanban Implementation
• Decision 5: Supplier Management - Total Cost of Ownership
• Decision 6: Inbound Logistics - Inbound Logistics Strategy

Day 2 (Afternoon)

• Supply Chain Collaboration
• Mapping the Future State
• Barriers to Implementation