Lean warehousing and materials procurement

Two days in which to learn and apply the logic and tools of Lean World Class® to warehouse optimization and materials management (finished goods, components and raw materials) based on the characteristics of the logistics-production process. The main objective is to reduce costs and improve the level of service.

OBJECTIVES

By the end of the course, participants will have learned:

• Lean Warehousing logic and tools to optimize the management of materials and their flows
• Theories and techniques for cost reduction

PROGRAM

The logistic-productive models

Classification of materials

• The Classification of Materials According to the Principles of WCL (World Class Logistics)
• Plan For Every Part setup to comprehensively manage material data

Material management criteria

Management of stock levels

• Methodologies for Stock Reduction
• Stock assessment indicators

Factory layout and ergonomics of workplaces

• Principles behind re-engineering of production lines: Golden Zone and ergonomic conditions for the purpose of NVAA reduction
• Standardization of packaging and introduction of modular racks as a tool for increasing line productivity
• Factory layout analysis in order to optimize internal logistics flows (5S - 5T)

Internal Logistics Flows

• Definition and optimization of internal factory logistics flows (from warehouse movements to line subservient flows)
• Analysis and ideological concept of internal storage areas (warehouse - supermarket - picking area - wip area)
• Analysis of material call systems
• Internal handling systems (Bull - Forklift - AGV - Low cost automation)

Warehouse and Service performance

• Internal warehouse KPIs
• Service KPIs: reliability, timeliness and regularity of delivery

Logistic Cost Deployment

• Analysis of losses divided by 3 Macro areas:
• Inventory
• Material Handling
• Transportation

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