Chapter Two - Lean Logistics
Chapter Two - Lean Logistics
Lean Logistics
Chapter Two
2
What is Lean Logistics?
▪ Lean logistics
▪ a way to recognize and
eliminate wasteful
activities from the
supply chain in order
to increase product
flow and speed and
maximize customer
value
3 What is lean thinking?
▪ Lean Thinking is a business methodology that originated
in the Japanese automotive industry during the late 1980s.
▪ The core idea is to maximize customer value while
eliminating waste from all processes.
▪ Simply put, Lean means creating more value for your
customers with fewer resources.
▪ Lean has also made its way into logistics. The concept is
known as Lean Logistics and has become a popular term
in supply chain management
4
What is Value?
➢the importance, worth,
or usefulness of
something.
➢principles or standards
of behaviour;
➢one's judgement of
what is important in
life
5 Value Parameters…Diverse
6 What is Customer Value?
7 Customer Value in Mobile
8 Lean Thinking –Business Model
9 Lean thinking
[1]Specify value:
▪Customer value
is identified and
added along the
supply chain
network.
10 Lean thinking
[2] Map out value stream:
▪ Identifying all processes along the supply chain
network in order to eliminate the processes that do
not create value to the overall product.
▪ This mapping helps us understand how the value is
created into the product from the customer’s
perspective.
11 Lean thinking
Corporate
Objectives &
Strategy
PEST SWOT
Competitive
Strategy
marketing production
finance logistics
42 Logistics Functions
▪ Order Processing
▪ Order processing is the transmission of customer requirements to the supply chain
▪ Accurate information is needed to achieve superior logistical performance
▪ information technology will facilitate it
▪ Responsive supply chains require accurate and timely information about customer purchase
behavior
▪ Fast information flow enables improved work balancing
▪ two areas of logistical work driven by information
▪ Forecasting and
▪ Communication of customer requirements
▪ The more responsive the supply chain design,
▪ the greater the importance is of accurate and timely information regarding customer purchase behavior
▪ customer requirements are transmitted in the form of orders
▪ from initial order receipt, delivery, invoicing, and collection
Logistics Functions of Logistics….
43
▪ Inventory
▪ Inventory requirements of a firm are directly linked to the facility network and the
desired level of customer service
▪ Inventory strategy seeks to achieve the desired customer service with the minimum
inventory commitment
▪ A sound inventory strategy is based on a combination of
▪ core customer segmentation,
▪ product profitability,
▪ 80/20 rule …..Pareto principle
▪ transportation integration,
▪ time-based performance,
▪ degree of commitment to deliver products rapidly to meet a customer's vs inventory requirement
▪ If products and materials can be delivered quickly……no inventory
▪ safety stock
▪ timely inventory replenishment
▪ supply chain costs incurred
▪ competitive performance.
44 Logistics Functions…
▪ Transportation
▪ is the operational area that geographically moves and positions inventory
▪ fundamental importance and visible cost
▪ traditionally received considerable managerial attention
▪ There are three basic ways to satisfy transportation requirements
▪ Operate a private fleet of equipment
▪ Contract with dedicated transport specialists
▪ Engage carriers that provide different transportation services as needed on a per
shipment basis
45 Logistics Functions…
▪ Transportation
▪ three factors are fundamental to transportation performance
▪ Cost
▪ Speed
▪ Consistency
46
Logistics Functions…
▪ Warehousing, Materials Handling, and Packaging
▪ facilitate the speed and overall ease of product flow throughout the logistical
system
▪ These work activities are integral parts of other logistical functions
▪ Inventory typically needs to be warehoused at selected times during the logistics process
▪ Transportation vehicles require materials handling for efficient loading and unloading
▪ Individual products are most efficiently handled when packaged together into shipping
cartons
▪ Effective integration of these functions facilitates the speed and overall ease of
product flow throughout the logistical system
47 Logistics Functions…
▪ Warehousing
▪ to store inventory
▪ Material Handling
▪ + many value- adding activities
▪ sorting,
▪ sequencing,
▪ order selection,
▪ transportation consolidation,
▪ product modification and assembly
48 Logistics Functions…
▪ materials handling
▪ Products must be received, moved, stored, sorted, and assembled to
meet customer order requirements
▪ The direct labor and capital invested in materials handling equipment
▪ mechanized and automated devices exist
49 Logistics Functions…
▪ Packaging
▪ master carton
▪ pallets, slip sheets, and various types of containers
▪ To facilitate handling efficiency
▪ serves to protect the product during the logistical process
▪ facilitates ease of handling by creating one large package
50 Facility Network
▪ The number, size and geographical relationship of facilities
used to perform logistical operations directly impacts customer
service capability and cost
▪ Types of facilities in the logistics network include:
▪ manufacturing plants,
▪ warehouses,
▪ cross-dock operations, and
▪ retail stores.
51 Facility Network…
▪ integrates information and transportation capabilities
▪ processing customer orders,
▪ warehousing inventory, and
▪ materials handling
The scope of integrated logistical operations
52
Inventory Flow
Information
Flow
Logistical Integration
Inventory flow
Responsiveness
Variance reduction
Inventory reduction
Shipment consolidation
Quality
Life cycle support
57 Logistical Operations
▪ Market distribution
▪ Manufacturing support, and
▪ Procurement
58 Logistical Operations …
▪ Market distribution [1]
▪ Movement of finished product to customers
▪ Timing and geographical placement of inventory become an
integral part of marketing distribution
▪ Link manufacturers, wholesalers, and retailers into supply chains to
provide product availability
▪ Helps to assist in revenue generation by providing strategically
desired customer service levels at the lowest total cost.
59 Logistical Operations …
▪ Market distribution[1]…
▪ The activity requires performing the following:
▪ order receipt
▪ processing deployment of inventories,
▪ storage and handling, and
▪ outbound transportation within a supply chain
▪ It shares the responsibility to coordinate in the areas of marketing
planning including:
▪ pricing, promotional support, customer service levels, delivery standards,
handling return merchandise, and life cycle support.
60 Logistical Operations …
▪ Manufacturing support[2]
▪ This involves planning, scheduling, and supporting
manufacturing operations such as:
▪ master schedule planning
▪ performing work-in-process storage,
▪ handling, transportation, and sortation, sequencing and time
phasing of components.
61
Logistical Operations …
▪ Procurement[3]
▪ This activity involves obtaining or sourcing products and materials from outside
suppliers.
▪ Key activities include:
▪ resource planning,
▪ supply sourcing,
▪ negotiation,
▪ order placement,
▪ inbound transportation,
▪ receiving and inspection,
▪ storage and handling, and
▪ quality assurance.
62 Logistical Operations …
▪ Procurement[3]
▪ It also shares the responsibility to coordinate with suppliers in the areas of
▪ scheduling,
▪ supply continuity,
▪ hedging, and
▪ speculation, as well as research leading to new sources or programs.
▪ The primary procurement objective is to support manufacturing or resale
organizations by providing timely purchasing at the lowest total cost.
Logistical Operations …
63
▪ Information Flow[4]
▪ It integrates the three operating areas:
▪ Market
▪ Manufacturing
▪ Purchasing
▪ Within individual logistics areas, different movement requirements exist with
respect to
▪ size of order,
▪ availability of inventory, and
▪ urgency of movement.
▪ It has two major components:
▪ planning/coordination and
▪ operations
64 Logistical Operations…
▪ Information Flow[4]
▪ Planning/Coordination: This involves identifying the required operational
information to facilitate Supply Chain integration via
▪ Setting strategic objectives,
▪ Identifying capacity constraints,
▪ Specifying logistical requirements,
▪ Managing inventory deployment,
▪ Specifying manufacturing requirements,
▪ Providing procurement requirements, and
▪ Forecasting demand.
65 Logistical Operations…
▪ Information Flow
▪ Operations information involves:
▪ order processing,
▪ order assignment,
▪ distribution operations,
▪ inventory management,
▪ transportation and shipping, and
▪ procurement.
66 Logistical Operating Arrangements/Structure
• Very common with “factory-less” companies like Nike and Best Buy
76 Flexible Structure…
➢ The customer-specified delivery facility might be near a point of equal logistics
cost or equal delivery time from two different logistics facilities
➢ The first is when a customer is at an equal spot between two logistic facilities.
➢ It is important to have a system than utilizes system capacity by balancing
workloads while protecting customer service levels.
Lean
Concepts
99 Performance cycle synchronization
▪ Delayed or faster performance at any point along the supply
chain results in potential disruption of operations
▪ Once consistent operations are achieved, managers can focus
on reducing the time to complete the performance cycle to a
minimum
100