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Course Overview and Strategic Alignment

Program Introduction: Wall-to-Wall (Four-Wall) Inventory for Supply Chain Leaders

Strategic Fit and Operating Paradigms for Wall-to-Wall Inventory

Diagnosing Current State and Feasibility

Value Stream Diagnostics and Feasibility Assessment

Regulatory, Quality, and Compliance Readiness

Designing the End-to-End Flow

Flow Architecture: From Receiving to Finished Goods Without Formal Stockholding

Data-Driven Parameters: Takt, Lead Time, and Buffer Strategy at Constraints

Integrated Planning: Demand, Supplier Scheduling, and Production Sequencing

Quality Release, Traceability, and Digital Controls in Four-Wall Flow

Implementation and Operating System

Operational Controls, Visual Management, and Daily Management System

Transformation Roadmap and Change Management

Digital Modeling and Continuous Improvement

Digital Performance Model: Simulation, Capacity, and Variability Analysis

Assessment and Mastery

Comprehensive Mastery Quiz: Wall-to-Wall Inventory

Quiz: Diagnosing End-to-End Flow and Constraints

Quiz: Regulatory and Quality Controls in Non-Stockholding Environments

Quiz: Flow Architecture and Physical Design Without Formal Stock

Quiz: Takt, Lead Time, and Buffer Strategy at Constraints

Quiz: Integrated Planning and Supplier Scheduling for Continuous Flow

Quiz: Quality Release and Exception Handling While Preserving Flow

Quiz: Operational Controls and Daily Management System

Quiz: Digital Performance Modeling and Variability Management

Capstone Quiz: Designing a Wall-to-Wall Operating Model and Roadmap

Wall-to-Wall Inventory Mastery: Designing Continuous Flow Operating Systems is a practitioner-built program for leaders who need to eliminate traditional stockholding while improving service, cost, cash, and quality. Instead of parking materials in warehouses and stockrooms, you will architect end-to-end flow from receiving to shipping using right-sized point-of-use staging, digital controls, and constraint-focused buffers. Across six sections, you’ll learn how to diagnose current-state feasibility, align with enterprise strategy, model capacity and variability, and implement a four-wall operating system that sustains performance under real-world disruption. The course blends lean, TOC, and modern MES/ERP/WMS practices to enable immediate quality release, tight supplier synchronization, and data-driven sequencing without creating formal inventory. By the end, you’ll set takt, WIP caps, and CONWIP loops; design compliant, audit-ready non-stockholding controls; and stand up the daily management and governance needed to maintain continuous flow. If your mandate is faster lead times, lower working capital, and rock-solid compliance—without building more storage—this course gives you the blueprint, the math, and the operating cadence to make wall-to-wall flow your competitive advantage.

Wall-to-Wall Inventory Mastery: Designing Continuous Flow Operating Systems

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            <p>Wall-to-wall inventory—also known as four-wall inventory—redefines how materials move through a facility by eliminating traditional stockholding areas and enabling continuous, constraint-aware flow from receiving to shipping. This course equips supply chain managers to design and operate such systems with strategic clarity and operational rigor, aligning decisions to enterprise outcomes across service, cost, cash, quality, and compliance. You will learn when a four-wall model is appropriate by demand profile, product characteristics, and regulatory context; how it contrasts with push, pull, JIT, CONWIP, and constraint-driven paradigms; and what governance, decision rights, and policies are necessary to sustain flow without building formal inventory positions.</p>

<p>The program is structured to move from diagnosis to design to deployment. You will begin by mapping end-to-end value streams, quantifying constraints (capacity, changeover, uptime, quality release, logistics), and assessing feasibility, including GxP and other regulated requirements such as traceability, labeling, and digital release. From there, you will architect a non-stockholding flow: define flow units and decoupling points; right-size point-of-use staging; select conveyance and supermarket alternatives; and set data-driven parameters for takt, capacity, WIP caps, CONWIP loops, and constraint buffers that compress lead time and reduce variability. Integrated planning content translates demand into supplier cadence, dock schedules, and heijunka-based sequencing, supported by supplier collaboration, ASNs, and synchronized transportation. You will design quality strategies for immediate or rapid release, implement digital travelers and status control in MES/ERP/WMS, and establish nonconformance pathways that preserve flow. The implementation segment builds the daily management system—kanban/CONWIP signals, andon, tiered huddles, standard work, and deviation response—while the transformation roadmap covers phased pilots, capability building for planners, buyers, operators, and quality teams, and governance updates with value realization tracking. A digital performance model guides simulation, capacity and variability analysis, and kaizen prioritization under disruption. Mastery is reinforced through targeted quizzes and a capstone assessment focused on designing an end-to-end wall-to-wall operating model and execution roadmap.</p>
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