“Excellent! This is an excellent class that needs cross-functioned group participation (Ops, ME, Material Flow, Supply Management, Supervisors). Excellent instructor!”
Wade — John Deere
At Toyota Material Handling, Columbus, IN
Mixed Model Material Flow — 3‑Day Immersive Workshop
August 18–20, 2026. Design a shortage‑resistant material delivery system for high‑mix production using PFEP, pull signals, route design, and standard work—supported by two Toyota factory tours focused on material flow.
Agenda — Learn it. See it. Bring it home.
Day 1 — PFEP, signals, and planned quantities
- Why material flow is the biggest daily pain point—and why it limits every Lean initiative
- Principles of an optimum mixed‑model material delivery strategy
- Plan For Every Part (PFEP): building a part‑level design database
- Kanban basics and other replenishment signals (choosing the right method per part)
- Planned material quantities: balancing coverage with high inventory turns
Day 2 — Presentation, routes, conveyance, and containerisation
- Toyota Production System presentation + Factory Tour I (material flow focus)
- Workstation material presentation as part of workstation design
- Material conveyance options: hand delivery through tuggers and AGVs
- Designing delivery routes: cadence, “frequent trips & light loads,” and standard work
- Containerisation strategy and policies tied to PFEP
Day 3 — Supermarkets, roadmap, leadership, sustaining change
- Factory Tour II: supermarkets, overseas shipments, and Kanban card system behaviour
- Material Flow Roadmap: the checklist used for completeness and consistency
- High‑mix/low‑volume challenges and solutions
- Leadership practices that keep the system healthy and improving
- Sustaining change: practical next steps and rollout guidance
Download Full Agenda
Get the detailed PDF agenda including all session descriptions, timings, and exercises.
View Agenda PDF
The perfect venue
Why Toyota Material Handling (Columbus, IN)
This workshop includes two factory tours of Toyota Material Handling (TMH), the #1 manufacturer of fork trucks in North America and a benchmark mixed‑model operation. The tours focus on how the material delivery system is designed and sustained in practice—supermarkets, signals, routes, and standard work.
Two factory tours
See real supermarkets, pull signals, delivery routes, and point‑of‑use presentation working together as a system.
See real supermarkets, pull signals, delivery routes, and point‑of‑use presentation working together as a system.
High mix at scale
TMH’s environment—over 50 base models and thousands of options—makes it an exceptional place to learn mixed‑model material flow.
TMH’s environment—over 50 base models and thousands of options—makes it an exceptional place to learn mixed‑model material flow.
Design → reality
Each classroom decision is reinforced on the shop floor, so you can translate what you see into a roadmap you can execute back home.
Each classroom decision is reinforced on the shop floor, so you can translate what you see into a roadmap you can execute back home.
High-impact outcomes
Benefits of Mixed Model Material Flow
Material Flow is often the single most overlooked constraint on factory performance. When the delivery system is engineered—rather than improvised—you stabilise production, reduce inventory safely, and create capacity for growth.
Reduce shortages dramatically — Pull systems + PFEP + supply chain clarity remove root
causes. No heroics, no magic.
Free up working capital — Lower inventory with confidence by using planned quantities
tied to replenishment logic.
Integrate outside suppliers — Sustainable reductions require suppliers connected to
internal usage signals and cadence.
Overcome mixed‑model challenges — Design rules for high mix make variability
manageable—and can become a competitive advantage.
Reduce factory floor space — Shrink line‑side storage through better presentation,
containerisation, and replenishment design.
Standardise material delivery — Routes and standard work make delivery run like
clockwork; avoid false savings from long cycles.
Who should participate?
This workshop is 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.
We also recommend this workshop for your process design team—manufacturing and industrial engineers in particular—because line design needs to support optimum material delivery as well.
- Material Managers
- Material Delivery Specialists
- Supply‑Chain Professionals
- Manufacturing Engineers
- Industrial Engineers
- Operations Managers
What past participants say
James 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
Excellent! The content, the venue and the experience were amazing. Thank you so much for a wonderful experience.
Maria — Baptist Health
“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
“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
Register — August 18–20, 2026
The second Mixed Model Material Flow workshop will be held August 18–20, 2026 at Toyota Material Handling in Columbus, Indiana. Registration, pricing, and seat availability are handled through our Events Manager checkout.
Go to RegistrationNeed an invoice or group registration? Use the Contact link below.