Lean Purchased Material Flow


This 2 day workshop will teach you how to move and handle purchased parts from the receiving door to the shipping door. The focus is on designing and implementing a system that reliably supplies purchased parts to continuous-flow cells, small-batch processing, and traditional assembly lines. The design and management of all aspects of a comprehensive Lean material handling system are covered, including routing, kanban systems and parts markets, as well as sustaining and continuously improving the system.

Those who would benefit from attending this workshop include:

  • Material handling and production control personnel, managers, supervisors, operations and support personnel, and change agents.
  • Organizations that require purchased parts for production.
  • Organizations that have had some experience implementing lean elsewhere in the organization.


Through instruction, discussion, case studies and hands-on workshop exercises, this workshop uses realistic factory examples to provide the concepts and the practical know-how you need to plan and implement the transition to a Lean system. The use of formulas, forms, rules and checklists are reviewed in detail, as are the detailed steps for the design and implementation of a parts database, parts markets, pull systems and optimized routes.

What You Will Learn

Workshop content includes:

  • Developing and using a parts management database to drive and control inventory reduction and continuous system improvement.
  • Designing and building a purchased-parts market and managing inventory levels.
  • Parts movement and conveyance options from parts markets to manufacturing.
  • Designing optimal delivery routes.
  • Calculating material delivery times.
  • The types and uses of pull signals.
  • Creating and operating pull systems
  • Design for sustainability and continuous improvement:
  • Standard work for the materials department
  • System metrics and objectives
  • Closed loop management controls
  • Layered auditing
  • Continuous system improvement

Training Outcomes

This workshop provides the knowledge and tools needed to systematically develop, operate and continuously improve a facility-wide lean material delivery system for purchased parts. System benefits include:

  • Reduced costs:
    • Reduced material handling costs.
    • Less time and hassle retrieving parts.
    • Higher plant inventory turns.
    • Less inventory.
    • Fewer forklifts.
    • Less overtime.
    • Less expedited delivery costs
  • Higher production output:
    • Increased reliability: the right part, delivered on time and in the right quantity to the operator
  • Improved safety:
    • Fewer forklift recordable incidents.


Training Overview

Our Courses

Manufacturing Control Systems

Quality & Environmental Systems

Strategy & Execution

Improvement Tool Kit

Presentation & Leadership Skills

Full Course List


SatiStar's Experience Makes The Difference!

  • . . . worked extremely well with the departmental and site managers . . . goal oriented and met the objectives set within the quoted budget and ensured the results were attained for the Company.

  • The guys from SatiStar did more in one week than we were able to do in 6 months.

  • Achieving ISO registration was far less onerous than we thought, our employees really rallied to the cause. The registration effort really brought us closer together as a team, and SatiStar really came through for us when we needed them.

  • We started this process a year ago with Mickey helping us create a spaghetti map of our processes on the whiteboard, and then his team guided us through their streamlining methodology and got us to where we are today. Our processes now look nothing like the spaghetti map – and we’re much more efficient today

  • This projected cycle time reduction of over 80% annual cost savings amounting to over 3% of sales, one-time savings of roughly $10 million, and working capital reduction of roughly $30 million really have us excited!

  • An outstanding success with Motorola’s vendor audit! What made this an exceptional achievement is that it typically takes 4 to 5 attempts to pass this audit. SatiStar’s expertise made it easy to avoid all the extra attempts.