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About the course

An enterprise product's value stream includes all actions to acquire materials, add value to make products, sell them, 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 supply chain's processes from an "extended" value stream perspective means looking at the total system, 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 (where we are now) you create a "visual" of supply chain systems flow. From this baseline, you can apply lean principles to create an improved future state (where we want to be) vision of an ideal just-in-time logistics value flow.

Course Objectives

At the end of the course participants will be able to:

  • Discuss just-in-time supply chain logistics principles, value, and value streams
  • Create a comprehensive current state value stream map of the company's "focus" dock-to-point of use (POU) supply chain value stream
  • Using actual case studies and team interactions, thoroughly analyze a product fabrication, a vehicle assembly, and a machine fabrication manufacturer from the last value adding step at the upstream supplier, through internal facility material management activities, to the material's point of use
  • Discuss key aspects of just-in-time supply chain operations, smoothed & balanced workload, visual process control, and flow kaizen principles and methodologies
  • Assist kaizen team members in understanding how JIT principles & methods can significantly improve materials flow within the "focus" supply chain value stream
  • Assist team members in visualizing, then designing an aggressive, feasible future state improvement 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

Course Outline

Day 1

Supply Chain Value Stream

  • Lean Flow Fundamentals
  • Conventional Supply Fundamentals
  • World Class Logistics
  • Just-in-time Supply Chain Fundamentals
  • Value & Value Streams
  • Base-lining Materials Activities
  • Known Supply Impediments
  • Traditional Supply Chain Operations
  • Value Stream Mapping Process
  • Dock-to-POU Value Stream Mapping
  • Dock-to-POU Case Study Examples
  • Supply Chain Value Stream Mapping
  • Cross-functional Mapping
  • Team Current State Mapping

Day 2

Current State Supply Value Stream Mapping

  • Team Dock-to-POU Current State Process Assessment
  • Team Dock-to-POU Current State Map Development
  • Team Dock-to-POU Current State Map Presentations
  • Group Dock-to-POU Current State Map Consolidation
  • Group Current State Map Opportunities
  • Group Final Dock-to-Dock Current State Business Process Design
  • JIT Supply Chain Principles & Methods
  • Smoothing Requirements
  • Orchestrating Flow
  • Enhancing Flow
  • Activity Cell Design
  • Visual Process Control
  • 2nd Day Progress Wrap-Up

Day 3

Just-in-time Supply Chain

  • JIT Supply Chain Principles & Methods
  • Continuous Flow
  • Pull Systems
  • JIT Facilities Design
  • JIT Transportation
  • JIT Material Handling
  • Improving Flow thru JIT
  • Integrating MRP into JIT
  • Feeder Activity Synchronization
  • Inter-Facility Material Management
  • Synchronizing Activities
  • Synchronizing Supplier Coordination
  • Just-in-time WIP Flow Demonstration
  • Dock-to-Dock Future State Mapping
  • Future State Case Studies
  • Supply Chain Future State Mapping
  • Team Dock-to-Dock Future State Process Improvement Assessment
  • 3rd Day Progress Wrap-Up

Day 4

Inventing a Better Future State Flow

  • Team Dock-to-Dock Process Improvement Assessment (Con't)
  • Team Dock-to-Dock Future State Mapping
  • Team Dock-to-Dock Future State Map Presentations
  • Group Dock-to-Dock Future State Map Consolidation
  • 4th Day Progress Wrap-Up

Day 5

Becoming Lean

  • Group Dock-to-Dock Future State Opportunities Discussions
  • Group Dock-to-Dock Final Future State Map Design
  • Group JIT Future State Supply Chain Impediments
  • Future State Performance Metric Discussions
  • Becoming Lean
  • JIT Supply Chain Future State Transformation Planning
  • Wrap-Up & Workshop's Value

Course Methodology

A variety of methodologies will be used during the course that includes:

  • (30%) Based on Case Studies
  • (30%) Techniques
  • (30%) Role Play
  • (10%) Concepts
  • Pre-test and Post-test
  • Variety of Learning Methods
  • Lectures
  • Case Studies and Self Questionaires
  • Group Work
  • Discussion
  • Presentation

Who should attend

This course is designed for anyone working in inventory and stock management and wants to implement JIT techniques more effectively.

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