Mixed Model Material Flow Workshop

Hosted at Toyota Material Handling
Columbus, Indiana

$1,995 per seat

Reserve Your Seat

Seating is limited to a maximum capacity of 32 students.

What Will You Learn at this Workshop?

Material Flow is the largest pain point in most factories. To make matters worse, materials also consume the vast majority of product cost -- sometimes upwards of 80%. And yet, Material Flow is regularly the single most overlooked aspect on the factory floor. We cannot stress this enough:

No matter how much time, money, and effort you put into implementing Lean practices, if your Material Flow is broken, your production line will NOT perform to expectations.

By the conclusion of this workshop, you will understand how to design a material delivery system that supports the management of a large number of different products, options, and items, with high efficiency and quality. We would go so far as to claim that your material delivery system, following our methodology, will essentially shortage-proof your production lines.

The tools of Mixed Model Material Flow can handle inevitable changes in mix and volume, without delaying or stopping the line. And they can do so efficiently, without overstaffing or wasteful material delivery activity.


Reduce shortages dramatically.

Reduce shortages dramatically.

Free up working capital by optimizing inventory.

Free up working capital by optimizing inventory.

Reduce factory floor space (by controlling inventory quantities).

Reduce factory floor space (by controlling inventory quantities).

Standardize your material delivery processes.

Standardize your material delivery processes.

Manage materials tightly in spite of high-mix challenges.

Manage materials tightly in spite of high-mix challenges.

Integrate outside suppliers on a pull system.

Integrate outside suppliers on a pull system.


"Excellent! This is an excellent class that needs cross-functioned group participation (Ops, ME, Material Flow, Supply Management, Supervisors). Excellent instructor!"
— Wade, John Deere

"I really found the workshop relevant to the work I do for my company. The sharing of ideas between companies through exercises was invaluable to my efforts."
— Chad, Boeing

"Richard and Gerard are both great teachers. It is clear how well they understand the material and Lean Manufacturing in general. The tours were also a big plus as we could see concrete examples of the discussed material handling strategies."
— Murphy, Loop Supply Systems

"Very good information on Kanban and PFEP!! Anyone that works in materials, even if it isn't management, could benefit from this course."
— Heather, Cummins

Who Should Participate?

This workshop has been designed for anyone responsible for designing, implementing, or managing the material delivery system or supply chain for a Mixed Model production line based on Lean principles.

  • Material Managers
  • Material Delivery Specialists
  • Manufacturing Engineers
  • Supply-Chain Professionals

Workshop Schedule

Day 1

Introduction to Material Flow Strategy

For most manufacturing companies, the opportunities for material management improvements are large. The workshop starts with an overview of this important topic.

Principles of Lean Material Flow

In this lesson you will develop a deep understanding of the optimum material delivery workflow and strategy.

Plan For Every Part

You probably have most of the material-related information that you will need, but can you see everything about a part in one place? Probably not. PFEP is a data analysis tool that you will want to create up-front, which will yield surprising benefits.

Kanban Basics

Your job as the designer of a material delivery system is to know which tool to use. Kanban is the Japanese work for "card" or more generally "signal", and this technique is at the heart of a Material Flow Pull System.

Replenishment Methods and Signals

Kanban means “signal”, and this signal can take various forms. As a material flow designer, you will need to know which signaling method to choose for an individual item. This information will be stored in your PFEP database.

Planned Material Quantities

One of the goals of Lean Material Flow is to balance material coverage (no shortages) with high inventory turns. In this lesson you will calculate optimum inventory levels for a variety of different items, using data and simple formulas. This information is stored in your PFEP database.

Day 2

Toyota Factory Tour

Start the day with a formal presentation about the Toyota Production System, and a tour of one of North America's best factories. The focus will be on the design and functioning of the material delivery system, with over 50 base models and thousands of possible options.

Workstation Design

Material presentation is a integral part of optimum workstation design. In this lesson you will review basic objectives and examples, as well as look at some provocative new ways to deliver and present materials to an operator.

Material Conveyance

The Material Flow designer will choose from a variety of Material Conveyance methods, from hand delivery to Automated Guidance Vehicles (AGVs).

Designing Delivery Routes

The philosophy of “frequent trips and light loads” will be accomplished through the design of your delivery routes. The establishment of Standard Work for material delivery is also applied in this step.


A formal containerization policy and strategy often does not get the attention and focus that it deserves. Every item in your PFEP database is associated with an optimal containerization plan.

Day 3

Toyota Factory Tour II

Return to the factory flow to view some of the unique aspects of this high-performing material delivery system: supermarkets, management of overseas shipments, and the functioning of the Kanban card system.

Design Principles and Optimal Material Management

Material Flow designers use a “roadmap” or checklist, for consistency and completeness. In this lesson you will learn the 10 Key Design Principles.

High Mix Low Volume Material Delivery

In the 21st Century many manufacturers are "high mix low volume", with many different but similar products that must be produced on the same line. The challenges to optimal material delivery in this environment are many, and solutions are covered in this important lesson.

Material Flow Leadership

The material delivery system needs continuous vigilance and management. In this important lesson we will review the methods and practices needed to ensure that your system is on a path of continual improvement.

Achieving and Sustaining Change

In this final lesson we will return to the Lean Material Management roadmap, and offer some final suggestions for productive next steps.

A3 Audit

Our goal at the end of the workshop is that every company will have an action plan for an immediate improvement at their home factory.

Mixed Model Material Flow

Event Date 07-21-2020 8:00 am
Event End Date 07-23-2020 3:00 pm
Original Price $1,995.00
Discounted Price $1,695.00 (Until 06-26-2020 10:17)