Training on Lean Six Sigma for Logistics and Supply Chain

Module 1: Introduction to Lean Six Sigma in Logistics

• Defining Lean (waste reduction) and Six Sigma (variation reduction).

• The 8 wastes (DOWNTIME) in logistics: defects, overproduction, waiting, non-utilized talent, transportation, inventory, motion, excess processing.

• The DMAIC framework and its application in supply chain.

• Case Study/Hands-on Exercise: Walk through a sample logistics process (e.g., order picking) and identify examples of the 8 wastes, quantifying the impact of each.

Module 2: Define Phase: Project Charter and VOC

• Developing a project charter with clear problem statement, goals, and scope.

• Capturing the Voice of the Customer (VOC) internally and externally.

• Defining critical-to-quality (CTQ) requirements for logistics processes.

• Case Study/Hands-on Exercise: Create a project charter for reducing the error rate in a warehouse picking operation, defining scope, business case, and measurable project goals.

Module 3: Measure Phase: Process Mapping and Data Collection

• Creating detailed process maps (SIPOC, swimlane diagrams) for logistics flows.

• Identifying key metrics and developing a data collection plan.

• Understanding measurement system analysis (MSA) for logistics data.

• Case Study/Hands-on Exercise: Develop a SIPOC diagram and a data collection plan for the inbound receiving process at a distribution center, identifying the key metrics to measure (e.g., receipt time, accuracy).

Module 4: Measure Phase: Baseline Performance and Capability

• Calculating process baseline metrics: cycle time, first-pass yield, and defects per unit.

• Introduction to process capability in logistics contexts.

• Creating visual dashboards for baseline performance.

• Case Study/Hands-on Exercise: Calculate the baseline first-pass yield and cycle time for a sample order-to-delivery process, using provided data to establish a performance baseline.

Module 5: Analyze Phase: Root Cause Analysis

• Applying root cause analysis tools: 5 Whys, fishbone (Ishikawa) diagrams, and Pareto analysis.

• Using failure mode and effects analysis (FMEA) for logistics processes.

• Identifying critical inputs affecting key outputs.

• Case Study/Hands-on Exercise: Perform a root cause analysis on a high rate of damaged shipments. Use a fishbone diagram to categorize potential causes and a Pareto chart to prioritize the most significant contributors.

Module 6: Analyze Phase: Data Analysis and Hypothesis Testing

• Introduction to basic statistics for logistics: distributions, central tendency, and variation.

• Using hypothesis testing (t-tests, chi-square) to validate root causes.

• Analyzing transportation and warehouse data for patterns.

• Case Study/Hands-on Exercise: Use a t-test to compare the average transit times of two different carriers for the same lane, determining if there is a statistically significant difference.

Module 7: Improve Phase: Generating and Selecting Solutions

• Brainstorming and evaluating improvement ideas.

• Using Lean tools: 5S, Kanban, standard work, and mistake-proofing (poka-yoke).

• Piloting solutions and conducting cost-benefit analysis.

• Case Study/Hands-on Exercise: Design a 5S implementation plan for a warehouse packing station, including sorting, setting in order, shining, standardizing, and sustaining. Estimate the expected productivity improvement.

Module 8: Improve Phase: Implementation and Pilot

• Developing an implementation plan and piloting improvements.

• Using design of experiments (DOE) principles for complex logistics processes.

• Managing change and engaging frontline employees.

• Case Study/Hands-on Exercise: Develop a pilot plan for a new slotting strategy in a warehouse, defining success metrics, pilot duration, and a plan for measuring results before scaling.

Module 9: Control Phase: Sustaining Improvements

• Developing control plans and standard operating procedures (SOPs).

• Implementing statistical process control (SPC) charts for key metrics.

• Establishing process ownership and ongoing monitoring.

• Case Study/Hands-on Exercise: Create a control chart (e.g., p-chart or u-chart) for the error rate in a picking process and define control limits and response rules for when the process goes out of control.

Module 10: Lean Six Sigma Project Management and Culture

• Leading and managing improvement projects.

• Building a culture of continuous improvement in logistics.

• Preparing for Green Belt or Black Belt certification.

• Case Study/Hands-on Exercise: Present a full DMAIC project case study (based on course exercises) to a simulated leadership team, highlighting the problem, analysis, solution, and sustained results.