Supply Chain Management Series Lean Warehousing with Manny Cantone, LeanQuest www.scl.gatech.edu/leanwh
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Supply Chain Management SeriesLean Warehousingwith Manny Cantone, LeanQuest
www.scl.gatech.edu/leanwh
In partnership with
Lean Warehousing
Webinar Agenda
Topic DurationOpening / Introduction 5 minLean Principles and Capabilities 10 minLean Culture 5 minLean Storage 10 minLean Foundations 10 minJust-in-time (Small Batch Processing) 10 minQ&A 10 min
Introduction / Background• Manny Cantone:
Toyota:– TPS Expert Toyota North American Parts
Operations• Ontario, Ca. DC Experience• Hebron, Ky. DC Experience
Lean Quest, LLC:– Expert in Lean Methods
• Lean Warehouse• Lean Manufacturing• Lean Service
Typical Distribution NetworkInformation Flow
• Orders
Information Flow• Status• Transaction
Physical Distribution
Physical Distribution
TransportationSa
les
Polic
ies
and
Prac
tices
Natural Demand Variation
“The Bullwhip Effect”
Inve
ntor
yCo
ntro
l
Man
ufac
turin
g
Cons
umer
s
Lean Distribution Network
No – “Bullwhip”
Natural Demand Variation
Information Flow• Orders
Information Flow• Status• Transaction
Physical Distribution
Physical Distribution
TransportationSa
les
Polic
ies
and
Prac
tices
Inve
ntor
yCo
ntro
l
Man
ufac
turin
g
Cons
umer
s
Standardized Work
Build-In Quality
Visual Management
Go LookGo See
ContinuousImprovement
Culture
Just-In-Time
Principles
1st Capability System Design
2nd Capability Problem Solving
3rd Capability Knowledge Sharing
Lean Operating Principles & Capabilities
4th Capability Leaders Develop
Others 1,2 ,3
Lean Warehouse Implementation
CULTURECustomer First
Trust and RespectContinuous Improvement
Team DrivenLearning Centered
Principled Leadership
CULTURECustomer First
Trust and RespectContinuous Improvement
Team DrivenLearning Centered
Principled Leadership
Lean Warehouse Implementation
STORAGETechniques
CriteriaMethodsSlotting
Storage Maintenance
STORAGETechniques
CriteriaMethodsSlotting
Storage Maintenance
Lean Warehouse Implementation
FOUNDATIONSKnowing Your Business
StandardizationWork Site Organization
(5S)Visual Mgmt.
Continuous Improvement
FOUNDATIONSKnowing Your Business
StandardizationWork Site Organization
(5S)Visual Mgmt.
Continuous Improvement
Lean Warehouse Implementation
JUST IN TIMESmall batch processing
based on:Standard Work
Operations DiagramWorkload PlanningProgress Boards
JUST IN TIMESmall batch processing
based on:Standard Work
Operations DiagramWorkload PlanningProgress Boards
Course Description / AgendaDay 1 Day 2 Day 3
Lean Warehouse Overview Day 1 Quiz Day 2 QuizLean Supply Chain Framework
Lean Storage Planning Developing Standard Work Batches
Value Stream Mapping for the Warehouse
Lean Storage “Right Sizing”– Hands on exercise
Generating Operational Diagram
Warehouse Simulation Lean Warehouse Implementation Approach
Creation of Daily Operational Workload Plan
Lean Warehouse Values and Principles
Leader Standard Work and Visual Management
Development of a Progress Control Board
Warehouse and Built-In-Quality
Performance Management - Metrics
Warehouse Simulation
Course Description / Warehouse Simulation• Hands on warehouse simulation• Learn how to calculate space
requirements using Value Stream Parameters
• Feel the benefits of applying Lean Principles directly to the simulation
• See the benefits of synchronized operations
Typical Results
Before After
Safety Incidents
Before After
Quality Errors
Before After
Productivity-Shipping
Before After
Storage
HeadcountReduction
Lead TimeReduction
Sq. Ft.Reduction
WIP Reduction
IMPROVE ALLKEY
PERFORMANCEINDICATORS
Q&A
• Thank you…
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