Program Overview
This workshop is designed to help warehouse, stores, and supply chain professionals streamline operations by applying Lean thinking and 5S principles in warehousing environments. The course introduces concepts like value vs. non-value activities, Muda (waste), and flow optimization, alongside hands-on strategies to implement 5S (Sort, Set in order, Shine, Standardize, Sustain) across storage areas. Participants will identify common inefficiencies such as overstocking, excess motion, and space underutilization, and learn how to solve them through visual management, kaizen, and workplace audits. Real-life applications from automotive, pharma, and FMCG sectors are shared to reinforce learning.
Features
- Apply Lean principles to reduce waste and improve warehouse process flow
- Use visual controls and audits to drive continuous improvement
- Implement and sustain 5S practices to enhance workplace discipline and safety
- Identify and eliminate the 7 types of waste (Muda) in warehousing
Target audiences
- Warehouse Supervisors
- Plant SCM Professionals
- 3PL Operators
Curriculum
- 5 Sections
- 25 Lessons
- 1 Day
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- Lean in Warehouse – Context & Principles5
- 1.1Concepts: Waste types in warehouse (motion, waiting, over-processing, inventory)
- 1.2Keywords: Value Stream Mapping, Pull Flow, Takt Time, Visual Factory
- 1.3Situational Focus: Frequent material search & mix-up in stores
- 1.4Real-life Case: Tier-1 auto supplier reduced order cycle by 50% using lean layout
- 1.5Exercise: Identify 7 wastes in a warehouse operation video
- 5S in Warehouse – What It Means Operationally5
- 2.1Concepts: Sort, Set in Order, Shine, Standardize, Sustain
- 2.2Keywords: Shadow Boards, Visual Cues, Red Tagging, 5S Audit
- 2.3Store Focus: Raw Material Store, Tool Store, MRO Items, Finished Goods Area
- 2.4Case Study: Cement plant’s RM store eliminated obsolete inventory with 5S sorting drive
- 2.5Checklist: Store-wise 5S Implementation Toolkit + Red Tag Log Template
- Visual Management & Standard Work5
- 3.1Concepts: Location Labeling, Path Marking, Inventory Color Codes, SOP Boards
- 3.2Keywords: Kanban Card, QR Coding, Signage Logic, Poka-Yoke for picking
- 3.3Situational Insight: Tools & spares misplaced daily due to labeling confusion
- 3.4Real-life Case: Textile unit used visual workflows to reduce re-pick errors by 60%
- 3.5Template: Create standard work SOP for a pick-pack-dispatch process with visual aids
- 5S Audits, Governance & Culture Building6
- Linking Lean with Performance Metrics4
- 5.1Core KPIs: Order Accuracy, Cycle Time, Space Utilization, Daily Dispatch Rate
- 5.2Keywords: Lean KPI Tree, Visual Scoreboards, Time-to-Locate
- 5.3Case Study: FMCG warehouse reduced picker fatigue by eliminating zigzag walk paths
- 5.4Exercise: Build a lean warehouse dashboard with 4 key performance indicators
Instructor
