Just-in-time Logistics Flow Kaizen Workshop
(8 days)

Overview | Description | Example Agenda | On-site Coaching Available

Overview top
By creating an extended logistics flow current state map (how it is done today) you create a "visual" of the flow of materials and products through your enterprise's systems. From this baseline, you can apply just-in-time principles and practices at every stage of customer requirement service to create an improved logistics flow future state (how we want to do it in the future) vision of an ideal logistics value flow.

Description top
  • Discuss just-in-time logistics system principles, methods, value, and value streams
  • Create a comprehensive extended current state value stream map of the company's logistics systems' value streams
  • Using actual case studies and team interactions, thoroughly analyze a machining and a vehicle assembly manufacturer from the last value adding step at the upstream supplier, through internal facility value adding processes, to the customer
  • Discuss key aspects of just-in-time logistics system flow, smoothed & balanced workload, visual process control, and flow kaizen principles and methodologies
  • Assist kaizen team members in embracing how JIT logistics principles & methods can significantly improve materials & products flow within the logistics system
  • Assist team members in visualizing, then designing an aggressive, yet feasible improved logistics future state design and an aggressive transformation plan
  • Discuss effective techniques to manage a complete value stream and transform it to just-in-time principles and practices

An enterprise's logistics value streams include all actions to plan, acquire materials, add value to make products, then ship them to customers.

Each action in this chain of activities is either value adding (e.g., being fabricated) or non-value adding (e.g., being transported). "Seeing" your logistics system's processes from an "extended"  value stream perspective means looking at the total system and its links, not just a component. It means paying attention to improving the system as a whole, supplier to customer, rather than focusing on improving only an individual sub-component of the system.

By creating an "extended" current state map (How it flows today) you create a "visual" of how the logistics system flows. From this baseline, you can apply just-in-time principles to create an improved future state (how it should be done) vision of an ideal just-in-time logistics value flow.

Just-in-time logistics system flow kaizen is a straightforward process. You map the extended logistics system along a representative slice of the system's flow, design improvements through application of lean principles, then document your improvement vision by designing a future state vision describing the improved flow.

The results will be significant, revealing logistics system problems and opportunities which might otherwise go unnoticed.

Example Agenda top

Day 1: Setting the Stage

Introductions / Workshop Structure
Lean Logistics Flow Fundamentals
Value & Value Streams
Current Logistics Procedures
Known Current System Impediments
Current Logistics Management Systems
Current Performance Metrics
1st Day Progress Wrap-Up

Day 2: Extended Current State Value Stream Mapping

Logistics Value Stream Mapping Process
Logistics Stages
  Process Stage Aggregation
  Materials Planning
  Supply Chain
  Production Operations
  Finished Goods Inventory
  Product Distribution
Cross-Functional Process Mapping
Team Logistics Extended Current State Mapping Instructions
2nd Day Progress Wrap-Up

Day 3: Inventing a Better Future State Flow

Team Logistics Current State Process Assessment
Team  Logistics Current State Map Development
Team Logistics Current State Map Presentations
Group Logistics Current State Map Consolidation
3rd Day Progress Wrap-Up

Day 4: Future State Opportunities

Group Logistics Current State Opportunities
Group Final  Logistics Current State Map
Functional Information Needs
Functional Information Investigations
4th Day Progress Wrap-Up

Day 5: Just-in-time Cross Walks

Functional Information Investigation Reports
Lean Logistics Cross-walks
  Flow Principles
  Standardizing Activities
  Balancing Work
  Operating to a Tempo
  Regulating Flow
  Enhancing & Pacing Flow
  Sequencing Flow
  Work Area Continuous Flow
  Visual Process Control
  Pull Systems
  Quality Assurance
Cord Wire P/C Case Study
4th Day Progress Wrap-Up

Day 6: Just-in-time Logistics Design

Just-in-time Logistics System Cross-walks
  Value Stream Management
Logistics Flow Future State Mapping
Wild Cat Actuators Future State Vision
  Materials Planning
  Customer Service
  Materials Planning
  Supply Chain
6th Day Progress Wrap-Up

Day 7: Consolidated Future State

Wild Cat Actuators Future State Vision
  Production Operations
  Finished Goods Inventory
  Product Distribution
Team Logistics Flow Future State Mapping Instructions
Team Future State Logistics Improvement Assessment
Team Future State Mapping
Team Future State Map Presentations
7th Day Progress Wrap-Up

Day 8: Group Future State Mapping

Group Logistics Future State Map Consolidation Group
Final Logistics Future State Opportunities Discussions
Group Final Logistics Flow Future State Map
Group Logistics Future State System Impediments
Logistics System Transformation Planning
Wrap-Up & Workshop's Value

On-site Coaching Available top
To request this on-site Just-in-time Logistics Flow Kaizen Workshop, please contact Jim Price at (502) 570-2766 or (859) 351-3215 (mobile) or via email: .