We perceive lean management in logistics (lean logistics) as the elimination of waste (time, space, movements, inventory) and the maximization of value for the customer. The goal is to streamline the flow of materials and information.
Here are some specific examples of the implementation of lean tools in logistics:
1. Warehouse and handling optimization (5S, Kaizen)
Implementation of the 5S system: Creation of standardized, clean, and organized warehouse positions (Sort, Set in order, Shine, Standardize, Sustain). This includes clear labeling of shelves and floors and the introduction of a "visual workplace" where every employee
can immediately see if everything is in its place.
Reduction of unnecessary movement (Motion): Optimization of picking routes – fast-moving goods are placed closer to shipping, reducing the time spent walking by warehouse workers.
Visual management: Use of andon lights or digital boards
for immediate reporting of faults (e.g., stacker failure) or the need to replenish materials.
2. Warehouse processes and inventory (Kanban, JIT, Poka-Yoke)
Kanban system (pull system): Instead of a push system (moving goods based on forecasts), a pull system is used, where a signal (e.g., an empty KLT box) triggers the replenishment of goods only when they are actually needed.
Just-in-Time (JIT) deliveries:
Materials arrive at the warehouse or production line exactly when they are needed, eliminating the cost of storing excess inventory.
Poka-Yoke (Error-proofing): Implementation of systems that make it impossible to make mistakes. For example, weight control systems during packaging that do not
allow a shipment to be closed if the weight of the goods does not match, or barcode scanning upon receipt (prevents parts from being mixed up).
3. Internal transport and supply to production (Milk Run)
Milk Run (Regular collection): Instead of chaotic deliveries from different suppliers at different times, a regular truck route is established, which collects smaller quantities of parts from different suppliers or from the warehouse to production at fixed intervals.
This increases the fill rate of trucks and reduces the number of trips.
Use of Dolly Trucks: Use of pallet adapters and trucks (Dolly) for easy handling and quick unloading/loading in internal logistics.
4. Automation and technology
Automated logistics system (AGS): Replacement of manually operated trucks with automated guided vehicles (AGVs) for routine material transport.
Voice picking / Pick-by-vision: Picking using voice commands or augmented reality, which increases picking accuracy and
speed.
Benefits of these measures
Reduction of inventory and tied-up capital.
Shortening of lead time – the time from order to delivery.
Increased picking accuracy and reduced error rate.
Improved work safety thanks to an
organized environment (5S).
We can help you streamline your warehouse processes and make them more efficient using LEAN techniques so that you have more control over your business, including stability and costs.