Curriculum
- 5 Sections
- 25 Lessons
- 1 Day
Expand all sectionsCollapse all sections
- 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