Lean Distribution: Applying Lean Manufacturing to Distribution, Logistics, and Supply Chain - Hardcover

by Kirk D. Zylstra (Author)

"Kirk Zylstra's focus on the customer is a fresh approach to lean. Companies that can bear the burden of variability will develop a strategic advantage in today's volatile market."
--Travis Jarrell Institute of Industrial Engineers Program Committee Chair

"Lean Distribution is a comprehensive yet concise work with clear leanings. Kirk's experience across a range of industries brings a unique understanding of common opportunities and solutions available to optimize distribution processes. Lean techniques, typically effective in manufacturing processes, are applied in the downstream supply chain in a practical and productive manner that will offer something to any business distributing tangible goods."
--F. Jeff Duncan Jr. VP, CIO, and Director of Technology Louisiana Pacific Corp.

"Lean Distribution has robustly captured the revolution occurring in today's increasingly competitive and global supply chain. Eliminating losses through lean manufacturing and lean distribution initiatives will become even more critical enablers to organizations developing cost-advantaged supply chains."
--Rick McDonald Director of Manufacturing The Clorox Company

Front Jacket

Many companies in diverse industries have implemented Lean manufacturing practices and successfully reduced operating costs, slashed inventories, reduced floor space, and improved customer service. However, few companies have successfully implemented Lean principles across distribution operations. The barrier: most distribution systems are based on inherently inaccurate forecasts that push inventory to warehouses to accommodate fluctuations in customer demand. This book shows how to break through the forecast accuracy barrier by applying proven Lean practices that reduce costs and simplify distribution processes.

Lean Distribution addresses the most challenging issues currently facing industry: forecast revisions and inaccuracies, customer demands to limit inventory exposure, and the need to reduce supply chain costs. Compounding these issues is the global sourcing firmly entrenched in industry. Global sourcing entails longer supply-chains, compounding the chronic limitations of forecasting, planning, and supply chain optimization. While these problems appear to have mutually exclusive solutions, Lean simplifies distribution operations and processes to bring results.

Lean Distribution resolves the forecasting dilemma and provides an actionable road map to transform the supply chain with specific recommendations to implement improvements. Lean embraces the variation and inaccuracy inherent in forecasts and customer orders to focus on reducing lead time, reducing lot sizes, and increasing reliability, yielding the flexibility and simplicity required to achieve consistent results. This book goes beyond describing the principles and a foundation to provide a comprehensive, real-world framework and specific recommendations for customizing a Lean approach to transform distribution in any business.

Derived from the author's experiences assessing product flow and implementing Lean principles in diverse companies and industries, Lean Distribution presents a proven, real-world approach to distribution--an approach that saves money and improves customer service.

Back Jacket

Many companies in diverse industries have implemented Lean manufacturing practices and successfully reduced operating costs, slashed inventories, reduced floor space, and improved customer service. However, few companies have successfully implemented Lean principles across distribution operations. The barrier: most distribution systems are based on inherently inaccurate forecasts that "push" inventory to warehouses to accommodate fluctuations in customer demand. This book shows how to break through the forecast accuracy barrier by applying proven Lean practices that reduce costs and simplify distribution processes.

Lean Distribution addresses the most challenging issues currently facing industry: forecast revisions and inaccuracies, customer demands to limit inventory exposure, and the need to reduce supply chain costs. Compounding these issues is the global sourcing firmly entrenched in industry. Global sourcing entails longer supply-chains, compounding the chronic limitations of forecasting, planning, and supply chain optimization. While these problems appear to have mutually exclusive solutions, Lean simplifies distribution operations and processes to bring results.

Lean Distribution resolves the forecasting dilemma and provides an actionable road map to transform the supply chain with specific recommendations to implement improvements. Lean embraces the variation and inaccuracy inherent in forecasts and customer orders to focus on reducing lead time, reducing lot sizes, and increasing reliability, yielding the flexibility and simplicity required to achieve consistent results. This book goes beyond describing the principles and a foundation to provide a comprehensive, real-world framework and specific recommendations for customizing a Lean approach to transform distribution in any business.

Derived from the author's experiences assessing product flow and implementing Lean principles in diverse companies and industries, Lean Distribution presents a proven, real-world approach to distribution--an approach that saves money and improves customer service.

Author Biography

KIRK D. ZYLSTRA is an independent consultant specializing in supply chain and manufacturing operations transformation. He teaches operations management and supply chain part-time at the University of Washington Business School in Seattle, Washington. He is a retired partner of a major international consulting firm, where he served major manufacturing, distribution, and retail companies during his more than twenty years with the firm. He has been a featured speaker at the Institute of Industrial Engineers (IIE) and other conferences on supply chain and Lean manufacturing. For more information about Zylstra and Lean transformation, visit www.profit-chain.com.