Just-in-time Distribution System Flow Value Stream Flow Kaizen
(4 days)

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

Overview top
Discover how to apply the principles of just-in-time to significantly increase the efficiency of operations as materials flow through your distribution center system.

Description top
  • Discuss just-in-time (JIT) distribution system flow & distribution center activity   profiling, and distribution center and system performance bench-marking
  • Using example case studies and team interactions, study several types of   distribution support system value streams from downstream customers through upstream suppliers
  • Develop an accurate “extended” current state map of the kaizen’s "focus"   distribution system value stream
  • Discuss key aspects of order-ship lead time, supply & distribution information   technology, visual distribution center operations, and JIT’s demand flow smoothing
  • Apply these JIT distribution principles and methods to facilitate team design of a feasible, yet aggressive distribution system "extended" future state map to improve flow within the kaizen’s "focus" distribution system value stream
  • Document flow impediments which must be eliminated through "process" or "point" kaizen to achieve the improved distribution system future state vision
  • Discuss effective techniques to manage the distribution system value stream’s transformation to Just-in-time principles and practices


To achieve these objectives, participants will:

  • Practice, through discussions and case study illustration, basic supply "extended" value stream flow mapping and flow kaizen concepts, team building, and kaizen process management
  • Develop, current & future state maps of the "focus" distribution system value stream
  • Document flow impediments which must be eliminated through process kaizen to achieve the future state distribution system flow design


A distribution system’s value stream includes all actions required track inbound shipments, receive, slot, putaway, store, maintain storage accuracy, pick, package, build shipments, and ship a customer’s desired items.

From your customer’s perspective, each stage in this chain of activities is either value adding (e.g., being picked) or non-value adding (e.g., waiting to be put away).  "Seeing" your distribution center’s mission from a value stream system perspective means understanding how customer requirements flow from a customer’s value perspective.  It means optimizing the entire system, from departing a supplier to arrival at your customer, rather than focusing on improving individual sub-stages or processes.

Distribution system value stream flow kaizen is a simple process.  You map the "focus" flow of the system through interviews, assessments, kaizen team collaboration, and graphically walking the flow from material suppliers through to customers including internal operations within distribution center(s) of the system by following orders from customers through all system stages, visually portraying each process in the flow of items and information

Example Agenda top

Day 1: Current State Value Stream Mapping

  • Introductions & Workshop Structure
  • Distribution System Fundamentals
  • World-Class Distribution Support
  • Just-in-time Distribution Fundamentals
  • Distribution Value & Value Streams
  • Base-lining Current Storage Activities
        - Supply System Process Profiling
        - Distribution Performance Bench-marking
  • Traditional Distribution Center Support
        - Receiving, Putaway, and Storage
        - Picking, Unitizing, and Shipping
  • Logistics Value Stream Mapping Process
  • Distribution Center Value Stream Mapping

 Day 2: Improving Flow & Process

  • Team Current State Assessment
  • Team Current State Map Development
  • Team Current State Map Presentations
  • Group Current State Opportunities
  • JIT Distribution Principles & Methods
        - Smoothing Customer Demands
        - Regulating Internal Sequencing
        - Enhancing Distribution Flow
        - Cellular Distribution Center Operations
        - Visual Distribution System & Process Management
        - Distribution Continuous Flow
        - Pull Systems
        - Material & Order Conveyance
        - Logistics Continuous Improvement
  • Improving Flow through JIT
        - JIT Distribution Management Systems

Day 3: Inventing a Better Future State Flow

  • Improving Flow through JIT (Con’t)
        - JIT Materials Receiving, Putaway, and Storage
        - JIT Order Picking, Unitizing, and Shipping
  • Distribution System Future State Mapping Process
  • Team Distribution System Future State Process Assessment
  • Team Distribution System Future State Mapping

Day 4: Sustaining Improvements

  • Team Distribution System Future State Map Presentations
  • Group Future State Map Consolidation
  • Group Future State Opportunities
  • Just-in-time Distribution System Performance Metrics
  • Distribution System Transformation
  • Wrap-Up & Flow Kaizen Value


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