Lean Warehousing

based on the lean pylosophy

ANALYSIS

Lean is a company mindset. A philosophy, but it is as practical as it can get. We evaluate the operation’s flows, activities and stats to spot waste. A set of actionable ideas are sketched.

PROJECT PORTFOLIO

The discoveries and ideas resulting from our first approach are filtered, detailed  and ranked to create a roadmap aligned with the company’s priorities, finite resources and culture.

IMPLEMENTATION

Either by coaching the leadership team or by directly managing the Lean portfolio plan and its change management strategy, we guarantee the expected results. We strongly encourage our customers to always consider Lean Transfer as a priority, which focuses achieving lean mindset sustainability.

GET RID OF WASTE. GEMBA!

Our Lean Warehousing method focuses on applying simple and practical tools enhanced by our personal industrial engineering signature. Waste is identified, root causes tracked and from the door opens to huge opportunities to set a continuous improvement mentality in the workforce, cut cycle times, increase service levels and quality, improve safety and promote ergonomics.

OUR VALUE OFFER

Shop floor transformation leads to better performance, resulting in savings, reduced complexity and healthy environment.
 
Overall warehouse and DC materials flow increases and streamlining.


Execution team alignment and momentum will drive other areas and people out of their comfort zone, promoting a dynamic change environment.

INCREASED PRODUCTIVITY BY 80%
SUCCESS STORY
WHAT WE FOUND

The customer’s most critical flow -order processing- could use improved floor policies to deal with exceptions, a specific layout area for orders that are ready and visual management tools to accelerate execution.

THE SOLUTION
  • 4 policies implemented.

  • 2 procedures designed and implemented.

  • Layout redesigned.

  • 3 necessary KPIs deployed.

  • 1 new zero-waste process launched and stabilized.

RESULTS
  • Astonishing 80% picking productivity increase.

  • Daily mileage traveled per picker cut from 10 to 4 miles.

  • Unsafe conditions in picking and product replenishment down by 70%.

THE STORY
 VALOR OBTENIDO 

Shoe manufacturer with exponential growth in the last 3 years. The original idea was to move to a higher facility. Together, we opted to take a deeper dive into the demand behavior and the related materials flow.

After 4 years, the company’s orders are processed in the same warehouse facility, and Lean Warehousing is part of the company’s core strategy.

Processes and infrastructure set the conditions for a safer work environment.

New KPIs demonstrate steadily rising performance for order processing.

Lean thinking creating a renovated culture in many areas as a ripple effect.