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Lean Distribution: Applying Lean Manufacturing to Distribution, Logistics, and Supply Chain
 
 
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Lean Distribution: Applying Lean Manufacturing to Distribution, Logistics, and Supply Chain [Hardcover]

Kirk D. Zylstra (Author)
4.0 out of 5 stars  See all reviews (7 customer reviews)

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Book Description

November 11, 2005 0471740756 978-0471740759 1
"Kirk Zylstra's focus on the customer is a fresh approach to lean. Companies that can bear the burden of variability will develop a strategic advantage in today's volatile market."
—Travis Jarrell Institute of Industrial Engineers Program Committee Chair

"Lean Distribution is a comprehensive yet concise work with clear leanings. Kirk's experience across a range of industries brings a unique understanding of common opportunities and solutions available to optimize distribution processes. Lean techniques, typically effective in manufacturing processes, are applied in the downstream supply chain in a practical and productive manner that will offer something to any business distributing tangible goods."
—F. Jeff Duncan Jr. VP, CIO, and Director of Technology Louisiana Pacific Corp.

"Lean Distribution has robustly captured the revolution occurring in today's increasingly competitive and global supply chain. Eliminating losses through lean manufacturing and lean distribution initiatives will become even more critical enablers to organizations developing cost-advantaged supply chains."
—Rick McDonald Director of Manufacturing The Clorox Company


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Lean Distribution: Applying Lean Manufacturing to Distribution, Logistics, and Supply Chain + Lean Logistics: The Nuts and Bolts of Delivering Materials and Goods + Lean Six Sigma Logistics: Strategic Development to Operational Success
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Editorial Reviews

Review

"...arguement it advances is that traditional forecast-driven approaches to supply chain management are inappropriate in today's turbulent markets." (Supply Management,, March 2006)

"... would recommend it ...to understand ... fundamentals of making the transformation from a production "push" to a demand "pull" supply chain." (Supply Management, April 2006)

From the Inside Flap

Many companies in diverse industries have implemented Lean manufacturing practices and successfully reduced operating costs, slashed inventories, reduced floor space, and improved customer service. However, few companies have successfully implemented Lean principles across distribution operations. The barrier: most distribution systems are based on inherently inaccurate forecasts that "push" inventory to warehouses to accommodate fluctuations in customer demand. This book shows how to break through the forecast accuracy barrier by applying proven Lean practices that reduce costs and simplify distribution processes.

Lean Distribution addresses the most challenging issues currently facing industry: forecast revisions and inaccuracies, customer demands to limit inventory exposure, and the need to reduce supply chain costs. Compounding these issues is the global sourcing firmly entrenched in industry. Global sourcing entails longer supply-chains, compounding the chronic limitations of forecasting, planning, and supply chain optimization. While these problems appear to have mutually exclusive solutions, Lean simplifies distribution operations and processes to bring results.

Lean Distribution resolves the forecasting dilemma and provides an actionable road map to transform the supply chain with specific recommendations to implement improvements. Lean embraces the variation and inaccuracy inherent in forecasts and customer orders to focus on reducing lead time, reducing lot sizes, and increasing reliability, yielding the flexibility and simplicity required to achieve consistent results. This book goes beyond describing the principles and a foundation to provide a comprehensive, real-world framework and specific recommendations for customizing a Lean approach to transform distribution in any business.

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


Product Details

  • Hardcover: 240 pages
  • Publisher: Wiley; 1 edition (November 11, 2005)
  • Language: English
  • ISBN-10: 0471740756
  • ISBN-13: 978-0471740759
  • Product Dimensions: 6.3 x 0.8 x 9.2 inches
  • Shipping Weight: 1 pounds (View shipping rates and policies)
  • Average Customer Review: 4.0 out of 5 stars  See all reviews (7 customer reviews)
  • Amazon Best Sellers Rank: #398,537 in Books (See Top 100 in Books)

More About the Author

Mr. Zylstra is an author, independent consultant, and retired Deloitte Consulting partner. During his 20 years consulting with Deloitte, he led the supply chain practice and worked with manufacturing and distribution companies across a wide variety of industries. His client engagements included: Lean Manufacturing, Supply Chain Management, Theory of Constraints, activity based costing and ERP implementation. Kirk has taught operations management, quality and project management at the University of Washington's Business School.

John Wiley & Sons published Kirk's first book: 'Lean Distribution: applying Lean Manufacturing to distribution, logistics and supply chain' in October 2005.

 

Customer Reviews

7 Reviews
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Average Customer Review
4.0 out of 5 stars (7 customer reviews)
 
 
 
 
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Most Helpful Customer Reviews

4 of 4 people found the following review helpful:
4.0 out of 5 stars A fresh perspective on Lean outside the factory, October 15, 2006
By 
Eric Schmidt (Louisville, KY, USA) - See all my reviews
(REAL NAME)   
This review is from: Lean Distribution: Applying Lean Manufacturing to Distribution, Logistics, and Supply Chain (Hardcover)
I found this to be interesting read on using lean principles to streamline the supply chain between the plant and the customer. Too often, Lean (like TOC, Six Sigma, etc.) is described by its followers as the magic solution for every problem. Refreshingly, Zylstra has not only addressed a specific topic, but also hasn't claimed that it always works perfectly and should never be questioned.

From a reader's perspective, the book is well written -- the case for lean distribution is made clearly through a series of brief chapters that serve as building blocks toward a logical, cogent conclusion.

By matching my own experiences to the methods and concepts presented in the book, there appears to be a great deal of "been there, done that" behind the author's positions. Many of the clients I have worked with -- and had great success with -- could benefit from spending some time with this book and thinking about how they could further improve using the concepts covered.

Overall, a pretty strong effort from what looks like a first-time author.
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1 of 1 people found the following review helpful:
5.0 out of 5 stars Lean Distribution is a "must have" text on supply chain optimization, April 11, 2007
This review is from: Lean Distribution: Applying Lean Manufacturing to Distribution, Logistics, and Supply Chain (Hardcover)
Zylstra has effectively packaged more than two decades of experience as a leading practitioner of production and supply chain optimization. Sharing client experiences has allowed Zylstra to add context to what at times is necessarily a technical path to getting the most out of your supply chain for both your organization and your customers. Lean Distribution is a "must have" text on how to successfully analyze and implement proven optimization techniques.
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1 of 1 people found the following review helpful:
4.0 out of 5 stars Excellent primer for how to do distribution right, January 2, 2007
By 
Dan (Oakland, CA) - See all my reviews
This review is from: Lean Distribution: Applying Lean Manufacturing to Distribution, Logistics, and Supply Chain (Hardcover)
This book is an excellent guidebook for how to setup distribution right the first time. I found many concepts inside that were highly applicable to my business which involves several different and complex distribution challenges due to compliance and lead time constraints. I would encourage anyone looking to setup a distribution network or rework one to read this book.
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Inside This Book (learn more)
Key Phrases - Statistically Improbable Phrases (SIPs): (learn more)
internal lead times, buffer strategy, customer order forecasts, replenishment orders, replenishment time, replenishment processes, flow commitment, replenishment cycle, warehouse labor, replenishment lead time, premium freight, customer service policy, customer lead time, replenishment quantity, demand variation, inventory targets, distribution requirements planning, buffer inventory, activity drivers, bullwhip effect, customer service policies, planning logic, delivery lead time, cost reduction efforts, delivered cost
Key Phrases - Capitalized Phrases (CAPs): (learn more)
Lean Pull, Lean Manufacturing, Six Sigma, Sourcing Capabilities, United States, Ending Inventory, Order Qty
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