Description
Book Synopsis"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.
Trade Review"... would recommend it ... to understand ... fundamentals of making the transformation from a production "push" to a demand "pull" supply chain." (
Supply Management, April 2006)
"...arguement it advances is that traditional forecast-driven approaches to supply chain management are inappropriate in today's turbulent markets." (Supply Management, March 2006)
Table of ContentsPreface xi
Acknowledgments xv
Chapter 1 Taking the Lean Approach 1
The Lean Change in Distribution 2
The RFID Change Dilemma 2
The Forecast Barrier 3
The Balancing Act 4
Business and Operational Plans 6
Forecast Accuracy 7
Another Approach 8
The Traffic Analogy 9
Improving Distribution Operations 13
Lean Paradigm Shifts 13
Book Approach and Contents 16
Lean Distribution Framework 17
Lean Distribution Transformation 22
Role of Information Technology 24
Applications for Lean Distribution 25
Summary 29
Chapter 2 Distribution Challenges 31
Customer Directions 31
Global Sourcing 33
Cost Reduction 33
Lean Streamlining 35
New Challenges? 36
Functional Silos 38
Summary 39
Chapter 3 Optimizing Distribution 41
Distribution Sports Franchise Analogy 42
Optimizing Distribution 43
Technology Infrastructure 48
Lowering Production/Sourcing Costs 55
Improving Inventory Management 56
Maximizing Asset Utilization 58
Technology Directions 63
Summary 65
Chapter 4 IT Transforms Distribution Processes 67
Distribution Business Processes 68
ERP Transformation 71
Summary 83
Chapter 5 Lean Operating Capabilities 85
The Lean Approach 86
Managing Uncertainty with Lean 92
Lean and DRP: Collaboration 98
Lean-Enabled Collaboration 104
Summary 109
Chapter 6 Customer Service Policy 111
Customer Service Policy 112
Segmentation 121
Service Strategies 125
Summary 127
Chapter 7 Buffer Strategy 129
Buffer Strategy 130
Determine Service Strategies 136
Service Distinctions 146
Summary 158
Chapter 8 Replenishment Cycles 161
The Pipeline Approach 162
Replenishment Time 165
Delivered Cost 170
Summary 183
Chapter 9 Pull Approach 185
Pull Trigger 187
Replenishment Orders 193
Inventory Targets 196
Buffer Management 198
Summary 204
Chapter 10 Conclusion 207
The Simplicity Challenge 208
Planning Transformation 209
Lean Distribution Benefits 211
Selling the Lean Distribution Vision 213
Implementing Lean Distribution 215
Index 219
