May 13-14, 2020 | Fontana, CA
September 30 – October 1, 2020 | Grapevine, TX
In this workshop, you will learn how to develop a storage environment that enables a conventional distribution facility with improved efficiency, quality, safety, and space utilization.
- Lean Warehouse Overview
- Simulation/Round 1: Traditional Operation Lean Storage
- Gemba walk & benchmarking – LeanCor Distribution Center
- Simulation Round 2: Operation After Lean Benchmarking
- Group Storage Exercise
- Lean Implementation Framework
- Process Implementation Phases 1-3: Standardize/Stabilize current state, future state standardized work, group exercise, and future state operational design
- Process Implementation Phases 4-5: Synchronized operations, exercises, and stabilize/improve processes
- Simulation/Round 3: Lean Warehouse Operation
- Summary and reflection
|Date(s)||May 13-14, 2020|
September 30 - October 1, 2020
|Duration||8:00 a.m. - 4:00 p.m.|
|Location||May 13-14, 2020|
14613 Bar Harbor Rd
Fontana, CA 92336
September 30 - October 1, 2020
Mercedes-Benz USA Warehouse
4303 Lakeside Pkwy
Grapevine, TX 75052
|Cost||$1,600* (Includes all materials, breakfast, lunch and snacks each day)|
In this highly interactive two-day workshop you will learn the key steps for implementing lean principles and converting a traditional warehouse operation. Hands-on participation in a simulation will teach you how to apply the tools so you can repeat the application in your environment.
Companies applying these principles, components, steps, and tools have experienced operational improvements in reduced internal damage and injuries along with improved storage and operational efficiencies of 15% to 30%.
“I was familiar with the concepts and tools introduced in class, and had even implemented some of them … However, the Warehousing course still introduced me to new ideas and material that I wish I would’ve had in my knowledge-bank prior to the facility launch. This gemba-based workshop is a very good, high-level type training on how to implement Lean principles (level flow, small batch sizes, quality at the source, standard work) into a warehousing environment, and the exercises and gemba walk of a facility made it possible to see these principles and tools in practice. Also, the instructors were passionate about the material and have experience in the field, which makes the workshop a lot more enjoyable”
-Ana Bailey, Supply Chain Engineer
This workshop combines lecture, gemba experience, group discussion, participative simulations, and group exercises to reveal the key steps for implementing lean principles in a traditional distribution operation. We created an experiential learning environment which allows the participants to understand – through the series of rapid PDCA cycles – the phases and steps to transform your operational processes in order to improve customer service, reduce costs, and provide a problem-solving environment for continuous improvement. Progressing through our three-round simulation, you will identify changes, implement them, and measure the impact of applying lean tools and principles to distribution processes.
- Round 1: reflects a conventional distribution center and its impact on customers, associates and management
- Round 2: reflects a distribution center after a Lean benchmarking trip taken by management
- Round 3: will reflect an operation after lean storage techniques and processes have been implemented
Both operating systems are evaluated and compared for on-time deliveries, lead time, quality, efficiency, distribution center space and equipment utilization, and cost per shipping line.
All levels of management from vice president to supervisor, change agents, professional staff, and hourly associates from organizations at any stage of a lean journey in a distribution center operation.
Learn more about the instructor(s) who will be leading you through this workshop.
David’s lean knowledge came from 17 years with the North American Parts Operations Division of Toyota, where he applied lean concepts to the launch of a distribution center, the company’s largest, supplying all North American sourced parts. He also was responsible for teaching just-in-time concepts to North American distributors and dealers.
His Toyota responsibilities included creation of the Toyota Consulting Group to help the company’s North American suppliers, distributors, and dealers implement lean methods. While at Toyota, he applied pull and flow at the company’s second-largest distribution center and deployed just-in-time principles to dealerships in two regions of the U.S. He currently aids companies implementing lean through Lean Quest.
Luis has over 16 years of experience in the warehousing and distribution industry with 14 focusing on Lean Implementation. His lean journey started at Toyota’s North American Parts Operations Division where he spent 6 years in the network’s largest Parts Distribution Center and in the planning and launch of both National Parts Centers. His next seven plus years were dedicated to deploying Lean at Chrysler’s Mopar Distribution Network where Luis was responsible for the establishment of Mopar’s first lean model and lean deployment through the NAFTA Distribution Network.
Luis earned a Bachelor of Science in Transportation & Logistics at the University of Maryland.
Workshops begin at 8:00am and end at 4:00pm. Breakfast and lunch are provided with breakfast beginning at 7:30am.
Breakfast, breaks and lunch are included in your registration fee beginning with breakfast at 7:30am. You are on your own for dinner. LEI staff can provide advice on local restaurants and attractions in the area. Please inform LEI of any food allergies or specials needs.
Workshop attire is business casual
Our workshops are designed to cater to a limited number of participants. If you must cancel a workshop registration, you will be given a full refund up to four weeks before the workshop. A cancellation occurring within four weeks of the workshop will be subject to a $350 cancellation fee. LEI will not be held personally responsible for any incidental cost incurred (hotel, airfare, change fee, etc.). To cancel a workshop registration, please call us at 617-871-2900.
What to Expect After Registration
Immediately after registering, you will receive a confirmation email along with your receipt.
One week before your workshop you will receive an email from LEI containing a link to download an electronic version of your workshop manual. Please add firstname.lastname@example.org to your safe-senders list in order to ensure you receive this message.
When you receive your e-manual, you have the following options:
- Do nothing. You will be given a notepad and pen at your workshop and the slides and information contained in the electronic manual are the same that will be used by the instructor during your workshop.
- Print out a copy. If you prefer to have a hard-copy manual (we recommend double-sided), you may create one and bring it with you to your workshop.
- Download. Put the e-manual(s) on a iPad or other device. You may find a PDF-writer App useful in accomplishing this.
Please note that it is your decision to print, store, and access the e-manual before and during your LEI workshop. We will not be providing hard-copy manuals at the workshop and it is NOT required that you have a printed copy with you. If you are unable to perform any of these or need any assistance, please email LEI at email@example.com.
To find your workshop completion certificate, go to lean.org and log in to your member profile. If you do not know your password, you can click the link to have it sent to you. Once you are logged in, go to My Purchases at the top of the page and choose the Workshops tab.