Lean Materials, Warehouse & Logistics Management

Assist you in processing all goods movements and in maintaining current stock inventories

10 - 11 DECEMBER, 2017. NASSIMA ROYAL HOTEL. DUBAI. UAE

INTRODUCTION

Lean in material handling and control, from the shop floor and out into the extended supply chain, needs to be reexamined for two reasons. First, the
majority of lean efforts to date have been based on tools and their deployment. Instead, lean should be about principles, or thinking, including the
constant progress toward an image of the ideal state of the process. Many companies state this in training but in practice the focus is still on the tools.

The second reason is that lean in material management has always been an extension of lean in manufacturing. Just copying or extending lean
manufacturing can be a mistake. Instead, material-handling managers need to take a fresh look at what lean material management is all about.
Learn key concepts which must be integrated into any lean approach to material management.

This course will demonstrate how warehouse operations are a key enabler to a successful supply chain implementation and the s tarting point for a
transformation. It is critical to manage safety, quality and efficiency. Learn to leverage the lean supply chain modifications to improve customer
responsiveness and reduce operating costs and in doing so contributing to a supply chain that create a competitive advantage for a company. To
accomplish this goal, we must bring lean principles into the warehouse and distribution center.

Lean Logistics, simply put, can be described as a way to recognize and eliminate wasteful activities from the supply chain in order to increase
product flow and speed. In order to achieve Leaner Logistics; organizations need to implement leaner thinking. Organizations that incorporate lean
thinking into their supply chain can benefit from improved customer service, reduced environmental impact by reducing waste and even overall
corporate citizenship.

KEY TAKEAWAYS LEAN MATERIALS:

Youll learn how to implement a lean material-handling system for purchased parts that delivers precise quantities of parts, precisely when theyre
needed, to precisely where theyre needed the fingertips of production operators.

LEARNING OBJECTIVES: From conveyors to

At the end of the workshop you should be able to: stackers to shuttles,
choosing the right
Create and populate a PFEP (Plan For Every Part)
Calculate an appropriate number of kanban cards using a given formula automation can
Determine route travel time for system standardization convert your
Isolate the key elements of lean thinking to be used in the warehouse
Utilize lean tools to reduce waste in the warehouse warehouse into a
Create a warehouse operation based on visual management and real time problem solving
Reduce inventories in warehouse operations
sleek machine.
Create collaboration between warehousing and other functional areas
Tapping Technology To Improve Lean Warehouses
Reduce the Handling
Ensure you are Using the Right Storage and Shelving Solution
Just in Time, Every Time
Lean Fulfillment Stream Simulation
Value-Stream Map the extended enterprise
Calculate and make decisions based on "total cost of fulfillment" for the entire supply chain
Plan, calculate, and implement pull systems to drive material replenishment
Break down cross functional barriers for effective supply stream collaboration
Implement logistics concepts of increased delivery frequency, lot size reduction, and leveled flow
Lean for administrative offices that support logistics activates
Planning and executing lean logistics networks
Effective route design and carrier acquisition techniques
Labor planning and monitoring activity

Lean thinking involves a constant cycle of seeking perfection by eliminating waste and maximizing product value. This process means that en d-customers
dont pay for organization inefficiency and waste.

For further Information/Booking

PH: +603 20274751 Fax: +603 78651533 Email: waseem@mawaevents.com Web: www.mawaevents.com

MAWA EVENTS SDN BHD TRUSTED IN DELIVERING EXCELLENCE

Leisure Commerce Square - No 9. Jalan PJS 8/9, 46150 Petaling Jaya, Kuala Lumpur, Malaysia
 Lean Materials, Warehouse & Logistics Management

THE BENEFITS:

By applying the concepts and principles learned in this workshop, you will be able to:

Fewer material handlers

Less time spent by operators retrieving parts
Higher plant inventory turns By homing in on the
Less inventory
Fewer forklifts data, and focusing
Less forklift recordable incidents
Higher production output
on the perfect
Less overtime order, companies
Less expedited delivery costs
Reduce inventories in the warehouse can make wise
Reduce warehousing costs by as much as 25% decisions about
Implement lean in the warehouse
Create logistics collaboration between warehousing and other functional areas materials handling
Improve supplier performance and accountability automation.
Improve customer satisfaction and customer relationships
Drive lean supply-stream management and lean logistics through your organization
Reduce the total cost of fulfillment through the reduction of inventory, space, lead time, logistics costs, and increased fil l rates.
WHO SHOULD ATTEND?

Those who would benefit from attending this workshop include:

Production control and material-handling personnel, engineers, managers, supervisors, operations and support personnel, and change
agents
Organizations that have processes requiring purchased parts for production
Organizations that have had experience with value-stream mapping as well as implementing lean in other areas of their organization
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.
Lean Implementation Leaders, Logistics Managers, Supply Chain Managers, Material Managers, all senior management
This workshop is specifically for the manufacturer who is ready to go outside the four walls of their plant and connect the plant to the
supply base using Lean principles
YOUR SEMINAR FACILITATOR:

Andrew Cheah is a highly sought after Lean consultant who has worked with various multi-nationals Fortune 500 companies for more than 15
years in the areas of materials, supply chain management and production and operational planning. He has experience across a range of
sectors including Oil & Gas and Chemical, Electronics, Textiles, Food Distribution, and Logistics. Organizations he has worked with include Dell,
Schlumberger, MI Swaco, Chevron, Smith International, Petronas, DKSH, Phillip Morris, Azadea, Intel, SABIC, MEBCO, Al Bawardi Steel Industries,
Oman Cables, and Xerox.

Andrew has consulted in more than 20 countries throughout Asia, Middle East, Australia and New Zealand. He is a prominent speaker in many
supply chain, warehouse and lean six sigma conferences all over Asia, Middle East and Africa. Known for his engaging manner and effective
results-oriented training and consulting style, Andrew has helped both multinational and small medium enterprises implement Lean initiatives
successfully.

Andrew has helped clients turn around their warehousing management, reengineering their materials processes, carrying out fac tory-wide
barcode implementation, vendor-managed inventory (VMI), setting up Kanban pull system, reducing machine set up time by more than 50%,
improving factory space and improving production capacity. He also possesses wide knowledge in implementing SCM system solutions, barcode
solutions, Lean manufacturing, MES (Manufacturing Execution System), CRM and ERP system integration. He is highly regarded for his ability in
setting up material and planning systems for fast-paced electronics manufacturing operations.

Andrew specialized in utilizing Lean in improving clients supply chain and orders to fulfillment process. He has spent mo re than 4 years working
with a few prominent oil and gas companies to improve their cash flow, productivity and supply chain and warehouse optimizati on. He has
improved their Day Sales Outstanding (DSO) by 45% within 6 months. He has also assisted distribu tion companies in optimizing their warehouse and
distribution operations.

For further Information/Booking

PH: +603 20274751 Fax: +603 78651533 Email: waseem@mawaevents.com Web: www.mawaevents.com

MAWA EVENTS SDN BHD TRUSTED IN DELIVERING EXCELLENCE

Leisure Commerce Square - No 9. Jalan PJS 8/9, 46150 Petaling Jaya, Kuala Lumpur, Malaysia
 COURSE CONTENT:
Day 1: Lean Materials Management

Session 1: Understand the importance of supply chain in todays market situation

Current market situation has prompted great attention in managing the cost and performance of not the manufacturing operations but also the supply chain
operations
What are the current supply chain issues?
The impact of supply chain to your organization
The Bullwhip effect and how it impacts your organization. Learn also how others counter the effect
Utilizing different supply chain strategies to improve your organizations performance

Session 2: Developing your Lean supply chain to optimize your operations

Utilizing the effective Lean methodology to relook at your whole supply chain operations in order to improve and obtain better performance
Understand what is Lean supply chain and how it helps other organizations to improve
How to apply Lean five important principles
Identifying the gaps to a better optimized supply chain operations
Maximizing value added activities by eliminating wastes

Case Study: You will examine a case study of a multinational company that focus on using Lean continuous improvement methodology to reduc e their current
inventory holdings and free up cash in a short period of time.

Session 3: Positioning your inventory in a global supply chain to respond promptly to your market

Effective inventory management has become critical to companies as they strive to improve their customer service, cash flow and profit margins, whilst meeting
the challenges of global competition, product proliferation, shorter lifecycles and demand uncertainty.

Striking the most profitable balance among service levels, lead times, budgets, risks, and inventory costs
Linking supply chain management and corporate strategy to gauge your firms performance
Determining the key supply chain drivers and their inter-relationships with strategy and other functions of the company such as inventory management
Redesigning distribution networks to mitigate transportation time, cost and capacity constraints

Session 4: Optimizing you inventory to manage your business smartly, efficiently and cost effectively whilst generating more cash

Most companies are plagued with two problems - 1) too much inventory and 2) a poor customer service level. We will assess different methods of prioritizing
inventory so that we have not just inventory, but the right inventory.

Better managing your inventory and saving money through ABC inventory management
Different ABC analysis to optimize cash holding, space usage in warehouse, sales, etc.
Ensuring maximum stock availability with minimum working capital commitment
Planning for uncertainty by determining the best quantity to replenish periodic demand (safety stock), frequency of replenishment (Order Point) and
Min/Max

Group Exercise: Practical ABC Materials Analysis: You will be working in teams analyzing a data set to optimize the way you manage your inventory. Brainstorm on
different ways of analyzing your inventory to achieve your organizations key KPIs.

Session 5: Moving towards Lean from Reactive inventory management to improve customer fill rates and minimize inventory expenses

Reducing inventory without improving responsiveness can lead to unhappy or worst still ex-customers. We will discuss which Lean Best Practices to focus on to
get the most bang for the buck.

Improving manufacturing or supplier responsiveness by implementing Lean best practices

Maintaining exactly the right inventory, in the right place, at the right time
Creating a win-win situation by identifying and eliminating wasteful activities and streamlining processes
Ensuring the supply chain does not waste resources making products without corresponding levels of demand
Enabling the company to sustain smart inventory management for an effective and collaborative supply- chain system thereby augmenting productivity
and quality

Session 6: Optimizing supply chain performance and maximizing ROI by capitalizing on Consignment and Vendor Managed Inventory (VMI) and other creative
supply chain/ logistics strategies

Most suppliers believe that Consignment and VMI are tools that only benefit customers. In this session, we will demonstrate that properly applied consigning
inventory to your customers and introducing VMI can boost your business. The key words are properly applied. Learn how to avoid the pitfalls of consignment and
VMI that have haunted many a supplier.

Assessing the significance of information sharing in demand planning

Positioning Vendor Managed Inventory (VMI) as a suppliers best friend
Consigning your inventory to your customers at a profit
Strengthening ties and fostering partnerships between manufacturers and distributors

Session 7: Measuring inventory management performance for improvements

We will discuss how to get the most impact from metrics such as Cash-to- Cash Cycle and Inventory Turnover. Finally, we will discover ways to avoid overstocked
and obsolete inventory in the future.

Combining inventory turnover with other measurements such as customer service level and return on investment (ROI) to provide an accura te barometer of your
success
Freeing up tied-in cash that can be used for stocking other products that have the potential of generating additional profits
Evaluating the efficiency of inventory management using the concepts of inventory turnover and the number of day's inventory is held
Analyzing how implementing lean improvements frees cash to be of more value
 COURSE CONTENT:
Day 2: Lean Warehouse & Logistics Management

Session 1: Warehouse planning and control

Many warehouses are operated in a reactive mode. Forward planning and pro -active management will improve performance and add value to your supply
chain. In this session, trainer will discuss with delegates about methodologies for layout planning, facilities control and pinpoint the approaches for upgrading.
Warehouse Strategic planning
Utilizing ABC inventory planning to optimize your warehouse operations
Applying Pareto analysis to Inventory Management
Warehouse capacity planning
Warehouse design for optimal effectiveness

Case Study: Plan and design a Lean warehouse that optimizes their overall performance and capacity.

Session 2: Warehouse operations and improving the work methods

As organizations move from mass production and mass distribution to mass customization, creative approaches are needed in the management of warehouse and
distribution. This session will discuss various techniques for storage location and use of locator system controls to establish materials location and inventory control
guidelines to suit to your warehouse needs.
Goods receiving
Order picking
Stock location
Operating procedures
Performance measurement

Session 3: Stocktaking & stock checks to prevent inventory shortages that are costly to your organization

Stocktaking and stock checks are an essential procedure for ensuring that the inventory and logistics functions are being man aged and operated correctly.
Types of Stock-Take
Using 6S methodology to prepare for a more efficient stock take or cycle count
Common root causes of stock count and how to prevent them
How to set up cycle count effectively to improve your inventory accuracy
Utilizing barcodes and RFIDs to improve your inventory accuracy

Session 4: Warehouse shelving and pick face design

The pick face is the critical interface between the storage and distribution processes. Inefficient design will mean ineffici ent and costly operations. One key to
effective warehouse design is the relative dominance of picking or storage activities. Ideal picking requires small stock in dedicated, close locations, but th is
requirement works against storage efficiency.
Selecting the right warehouse shelving for your inventory
Pick trails and pick face layouts
Pick face technologies
Cross docking
Automated storage and retrieval system (ASRS)

Session 5: Storage and handling methods

Choosing the most appropriate medium to handling your requirement is a major issue in creating the optimum warehouse desig n. This session will review the storage
options and selections of the right storage equipment for your warehouse operation, and analyze different methods to maximize your efficiency.
Inventory segregation according to their different characteristics
Different handling methods and their risks
Handling first-in, first-out (FIFO) or first-expire, first-out (FEFO) inventory in your warehouse
Selecting the RIGHT equipment for your warehouse operations

Session 6: Latest Warehouse Operations

Utilizing the latest Lean concept and technologies to improve your warehouse performance
What is Lean warehousing?
Eliminating the common wastes in warehouse
Lean tools that will optimize the warehouse performance and inventory control
Combining Lean concept and latest technologies to improve warehouse performance

Case Study: Learn how world-class warehouses utilizing tools such as pick-to-light and voice-pick to increase their warehouse productivity.

Session 7: Integrating logistics management into warehousing and s upply chain activities for improved overall business success
Defining logistics management strategies and its importance for the business process
Implementing logistics management to control the flow of material movement through the supply chain and wareho using activities to minimize
operational cost
Recognizing the need for effective logistics management in warehousing to reduce inventory carrying cost
Develop your lean logistics strategy
Lean Materials, Warehouse & Logistics Management REGISTRATION FORM
10 - 11 DECEMBER, 2017. NASSIMA ROYAL HOTEL. DUBAI. UAE

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