Lean Material Handling is a two-day intermediate level workshop and is ideal for any organization that employs material handlers to deliver product within the organization. Workshop participants will create material delivery routes that will reduce the amount of raw material inventory within the value stream without hindering the value stream's ability to produce to customer demand. Lean Material Handling will reduce the waste of overproduction and allow for easy monitoring of pitch in Single Piece Flow work cells.

The time to travel each route will be timed so that the workload can be properly balanced amongst the material handlers. By removing waste from the current system, your organization will be able to make many more raw material and parts deliveries with the same material handling staff. The result is less inventory with a more level pull from stores. Thus, re-order points can be reduced since raw material inventory is withdrawn at regular intervals in small batches instead of large amounts at sporadic, unpredictable intervals.

Like most Lean Solutions workshops, Lean Material Handling combines classroom theory with case study simulations and a practical exercise to reinforce the training. A simulation is used to demonstrate the chaos and inefficiency of traditional material handling methods. Material handlers will be familiar with the chaotic manner in which materials are delivered, while supervisors and operators will relate to the amount of late and/or incorrect deliveries. Workshop participants then will create a material delivery route for the simulation. Most importantly, participants will create a material delivery route within your organization with less waste and more frequent deliveries.

• Review the Lean Principles
• Introduce several Lean Material Handling systems
• Simulate one of these systems
• Design a Lean Material Handling system within your facility

Day One

• Review of Lean Principles
• Introduction to Lean Material Handling
• Lean Material Handling Systems
  • Classroom Simulation: Traditional Material Handling
  • Introduce 4 Lean Material Handling Systems
  • Review Material Handling Issues

• Design a Lean Material Handling System

  • Classroom Exercise: Design a Lean Material Handling System for the Simulation Exercise
  • Practical Application: Design a Lean Material Handling System within your Facility
• Workshop Summary

Workshop participants will be able to design Lean Material Handling delivery routes within your facility with less waste and more frequent delivery of materials. Typical improvements include:

This workshop is great for operators, managers, supervisors, team leaders, and material handling and logistics employees. An ideal team consists of a sample from each of these areas. Participation of material handlers is critical as their knowledge is essential for creating an efficient Lean Material Handling delivery route. They will also be key in communicating the new methods to the rest of the production team.

Since Lean Material Handling is an intermediate Lean Solution, most attendees should have prior Lean knowledge. If Lean is new to your organization, consider starting your Lean journey with either Launching the Lean Initiative or Lean Principles. Although Lean Material Handling can be applied at any time, it is preferable to implement several Single Piece Flow work cells first. However, for some organizations Single Piece Flow is not applicable, so those organizations may ignore this prerequisite.

Most organizations do not apply Lean Material Handling until after they have achieved their first Future State. However, each company's Lean journey is unique; some organizations may require this workshop earlier in their Lean journey whereas others may not require it at all.

As with all our workshops, each participant receives their own workshop binder so they can keep their own notes for reference once the workshop is over. Participants also receive a Certificate of Completion to show that they have completed a Lean Solutions workshop.

The materials from the workshop may be redistributed within the company. Many organizations choose to hold short training sessions using these materials prior to designing new Lean Material Handling delivery routes so that all employees participating understand the concepts. Additional workbooks are also available (call for pricing).

You also receive a 100% guarantee! If you are not satisfied either with the material covered or the teaching style of the workshop facilitator, there will be no charge! If we fail to meet your expectations, the only thing you will be asked to pay for will be the expenses incurred.

Although our workshops are designed to give the knowledge to you and your team, follow-up days are recommended to review progress made following each workshop. Typical organizations require one to two follow-up days about 2-4 weeks following the workshop. These follow-up days also help to ensure that the principles learned during the workshop are not forgotten or neglected after the workshop is over. If you are interested in a greater involvement by one of our expert facilitators, check out our On-Site Lean Implementation solution.

The base cost for this two-day workshop is $7,000, which covers the first 15 participants. Classes larger than 15 participants will be taught by two facilitators and cost $11,000. In order to keep the class size manageable and to facilitate the learning process, Lean Solutions restricts the maximum class size to 30 participants. Follow-up days cost $1,500-$2,000 per day, depending upon the experience of the facilitator. There is a 10% discount available for long-term engagements. Expenses are in addition to the costs outlined above and include cost of travel and accommodation (if required) as well as meals and workbooks ($20 per participant).

Lean Solutions will tailor workshops to meet each company's requirements. Call or e-mail for more information or to schedule a workshop.