Introduction

In today’s competitive logistics landscape, companies must reduce waste, increase efficiency, and continuously improve their operations. Lean warehousing focuses on eliminating non-value-added activities, improving workflow, and enhancing productivity through methodical process optimization. By adopting lean principles, warehouses can minimize costs, reduce lead times, and ensure greater operational flexibility.

This course provides comprehensive training on Lean Warehouse principles, techniques, and tools, offering actionable insights for streamlining inventory control, storage optimization, workflow efficiency, and employee engagement. Participants will also learn to apply Kaizen, 5S, value stream mapping, and other Lean tools to create a high-performing, waste-free warehouse environment.

Course Objectives

By the end of this course, participants will be able to:
✅ Understand and implement Lean principles in warehousing.
✅ Apply 5S, Kaizen, and value stream mapping to warehouse operations.
✅ Optimize inventory flow, reduce waste, and improve space utilization.
✅ Drive continuous improvement with Lean metrics and performance tracking.
✅ Enhance workforce efficiency and engagement through Lean leadership techniques.
✅ Design a Lean-driven, high-performance warehouse system for the future.

Who Should Attend?

This course is ideal for:

• Warehouse & Operations Managers
• Supply Chain & Logistics Professionals
• Process Improvement Specialists
• Inventory & Distribution Managers
• Lean Six Sigma Practitioners
• E-commerce & Retail Supply Chain Leaders
• Operations Consultants & Engineers

Day 1: Introduction to Lean Warehousing

• What is Lean Warehousing?
  • Principles of Lean manufacturing applied to warehousing
  • Key Lean concepts: Value stream mapping, waste elimination, continuous improvement
• Understanding Waste in Warehousing
  • The 7 types of waste (Muda): Overproduction, waiting, transportation, unnecessary inventory, motion, defects, and unused talent
  • Identifying and quantifying waste in your warehouse
• Lean Warehouse Key Performance Indicators (KPIs)
  • Measuring efficiency, throughput, and lead time
  • How to align Lean metrics with business goals

Day 2: Lean Tools for Process Optimization

• 5S Methodology: Organize for efficiency
  • Sort, Set in order, Shine, Standardize, Sustain
  • Practical examples of implementing 5S in the warehouse environment
• Kaizen (Continuous Improvement)
  • Engaging the workforce in improvement initiatives
  • How to run Kaizen events to address specific issues in warehousing
• Value Stream Mapping (VSM)
  • Identifying value-added vs. non-value-added activities
  • Creating a current and future state map for Lean warehouse optimization
• Kanban Systems for Inventory Management
  • How to optimize stock levels, reduce overstocking, and prevent stockouts
  • Implementing just-in-time (JIT) techniques

Day 3: Lean Warehouse Design and Layout Optimization

• Designing a Lean Warehouse Layout
  • Flow-based warehouse design to reduce unnecessary movement and bottlenecks
  • Product categorization and slotting optimization
• Optimizing Inventory Storage
  • ABC analysis & dynamic slotting to maximize storage space
  • Vertical storage and rack design for efficiency
• Streamlining Order Picking and Packing Operations
  • Best practices for zone picking, wave picking, and batch picking
  • Implementing pick-to-light and RFID scanning technologies to minimize errors

Day 4: Lean Leadership & Workforce Engagement

• Lean Leadership & Team Engagement
  • Creating a culture of continuous improvement in the warehouse
  • Training teams to identify waste and implement Lean solutions
• Employee Empowerment and Involvement
  • How to encourage employees to make suggestions for process improvements
  • Case Study: Toyota’s employee-driven continuous improvement
• Standardized Work & Visual Management
  • Creating standard operating procedures (SOPs) for Lean activities
  • Visual tools like dashboards, kanban boards, and floor markings to communicate Lean goals

Day 5: Implementing and Sustaining Lean in Your Warehouse

• Building an Implementation Plan for Lean Warehousing
  • Setting realistic timelines and achieving milestones
  • Overcoming resistance to change in warehouse teams
• Evaluating the Impact of Lean Implementation
  • Measuring improvements: Time savings, cost reduction, error reduction, and productivity increases
  • Lean auditing for continuous feedback and monitoring
• Sustaining Lean in the Long-Term
  • Building a sustainability framework to maintain Lean progress
  • Leveraging technology for ongoing Lean improvements (WMS, robotics, automation)
• Capstone Project & Certification
  • Participants develop a Lean warehouse optimization plan for a case study warehouse
  • Final assessment and feedback session
  • Certification: Certified Lean Warehousing Specialist (CLWS™)

Certification

Upon successful completion, participants will receive the Certified Lean Warehousing Specialist (CLWS™) credential, validating their expertise in Lean principles, waste elimination, and continuous improvement within warehouse environments. This certification is designed to elevate their careers in operations management, logistics, and supply chain leadership.

Key Takeaways

✔ Master the core Lean tools such as 5S, Kaizen, and Value Stream Mapping.
✔ Implement waste-reduction strategies and improve workflow efficiency.
✔ Design optimal warehouse layouts that streamline operations.
✔ Foster a culture of continuous improvement and employee empowerment.
✔ Achieve measurable improvements in inventory control, order picking, and space utilization.
✔ Gain an industry-recognized certification for career advancement.