BECOMING 'LEAN' -- ROADMAP & IMPLEMENTATION.

The paper gives an introduction to lean principles and provides a roadmap for implementation in any distribution environment. A summary of the lean tools widely used and a lean tool selection matrix is also provided. The roadmap is then applied to a distribution facility to make the processes more efficient. In this paper, a 10-step lean problem solving approach is introduced and applied in detail to a distribution warehouse operation. Initial process study revealed several problem areas. Two of the most glaring problems a) High Customer Wait Time and b) Pending Days Sales Outstanding (DSO) were chosen for analysis. The 10 step method is then applied by first Value Stream Mapping (VSM) the current process to understand Customer Value Add (CVA), Business Value Add (BVA) and Non Value Add (NVA) activities. A future state Value Stream Map is proposed with the objective of eliminating Non Value Add activities and minimizing Business Value Add activities for overall lead time reduction. Potential improvement opportunities are identified and weighted based on their impact on the organization's Key Performance Indicators (KPIs). Standard Operating Procedures (SOPs) in the form of future VSMs are created and new employee productivity measures are introduced to ensure process control and employee accountability. The loop is then completed by selecting the next major process and applying the general framework to establish a culture of ongoing improvements. [ABSTRACT FROM AUTHOR]