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…