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

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9780471740759: Lean Distribution: Applying Lean Manufacturing to Distribution, Logistics, and Supply Chain
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"Kirk Zylstra's focus on the customer is a fresh approach to lean.Companies that can bear the burden of variability will develop astrategic advantage in today's volatile market."
—Travis Jarrell Institute of Industrial Engineers ProgramCommittee Chair

"Lean Distribution is a comprehensive yet concise workwith clear leanings. Kirk's experience across a range of industriesbrings a unique understanding of common opportunities and solutionsavailable to optimize distribution processes. Lean techniques,typically effective in manufacturing processes, are applied in thedownstream supply chain in a practical and productive manner thatwill offer something to any business distributing tangiblegoods."
—F. Jeff Duncan Jr. VP, CIO, and Director of TechnologyLouisiana Pacific Corp.

"Lean Distribution has robustly captured the revolutionoccurring in today's increasingly competitive and global supplychain. Eliminating losses through lean manufacturing and leandistribution initiatives will become even more critical enablers toorganizations developing cost-advantaged supply chains."
—Rick McDonald Director of Manufacturing The CloroxCompany

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From the Inside Flap:

Many companies in diverse industries have implemented Leanmanufacturing practices and successfully reduced operating costs,slashed inventories, reduced floor space, and improved customerservice. However, few companies have successfully implemented Leanprinciples across distribution operations. The barrier: mostdistribution systems are based on inherently inaccurate forecaststhat "push" inventory to warehouses to accommodate fluctuations incustomer demand. This book shows how to break through the forecastaccuracy barrier by applying proven Lean practices that reducecosts and simplify distribution processes.

Lean Distribution addresses the most challenging issuescurrently facing industry: forecast revisions and inaccuracies,customer demands to limit inventory exposure, and the need toreduce supply chain costs. Compounding these issues is the globalsourcing firmly entrenched in industry. Global sourcing entailslonger supply-chains, compounding the chronic limitations offorecasting, planning, and supply chain optimization. While theseproblems appear to have mutually exclusive solutions, Leansimplifies distribution operations and processes to bringresults.

Lean Distribution resolves the forecasting dilemma and providesan actionable road map to transform the supply chain with specificrecommendations to implement improvements. Lean embraces thevariation and inaccuracy inherent in forecasts and customer ordersto focus on reducing lead time, reducing lot sizes, and increasingreliability, yielding the flexibility and simplicity required toachieve consistent results. This book goes beyond describing theprinciples and a foundation to provide a comprehensive, real-worldframework and specific recommendations for customizing a Leanapproach to transform distribution in any business.

Derived from the author's experiences assessing product flow andimplementing Lean principles in diverse companies and industries,Lean Distribution presents a proven, real-world approach todistribution—an approach that saves money and improvescustomer service.

About the Author:

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.

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