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Designing & Managing A Lean Warehouse

Designing & Managing A Lean Warehouse

Lean Warehousing & Distribution

This workshop applies Lean Manufacturing concepts to warehousing and distribution operations. While storage and warehousing are often considered as waste, they can often add value of time and place while supplementing and enhancing Lean Manufacturing.

Participants will learn how to analyze their inventory and orders and develop more effective strategies for storage and picking. They practice this knowledge in the many exercises included in this seminar.

Program Summary

Format Onsite Workshop Online Who Should Attend?
Time 2-Day   Managers 
Warehouse Supervisors
Materials Managers 
Cost $5700 (Includes Travel) $4700
Participants 5-35 5-20
Next Step Call us at 816-931-1414
Warehouse Adds Value

Warehouse Added Value

A warehouse adds value of time, place and quantity that is not available from the manufacturer or supplier. Most warehouses receive large, infrequent loads and deliver smaller loads more frequently. A few warehouses such as grain elevators, receive many small loads and consolidate them into larger loads for train or barge transport.

Participants Will Learn...

  • How warehousing can add value.

  • How to eliminate the waste in warehousing & distribution.

  • About the many types of available storage methods and how to select the right equipment.

  • Three strategies for ord er picking and when to use each.

  • How to analyze your shipment and receipt orders and use this information to develop picking and storage strategies.

  • How much storage space to allocate for each item class.

  • How to layout an efficient warehouse.

  • About the wealth of data and information in the publication, NAVSUP 529. 

  • How to identify special facility requirements.

  • Warehouse Management Systems and how to select an appropriate system for your operation.

  • Inventory Record Accuracy and how to maintain it with Cycle Counting and process improvement.

  • How to conduct an efficient Physical Inventory.

  • How to conduct Work Sampling to identify wasted time.

  • How to develop and use time standards and where to find predetermined standard information.

  • Why the little things are often important.

Program Outline

1. Introduction

Adding Value Through Time & Place

The Role of Warehousing

2. Storage Methods & Equipment

Pallet Storage

Small Parts Storage

Other Storage

Material Handling Methods & Equipment

Pallet Handling

Case Handling

3. Order Picking

Streamlining Order Picking

Picking Strategies

4. Design Procedures

Product-Volume Analysis

Storage Requirements Analysis

Selecting Equipment

5. Warehouse Layout

Zoning & Space Requirements

Layout of The Warehouse

Warehouse Layout Exercise

6. Special Facility Requirements

Structural & Clear Height


Fire Protection

Hazardous Materials


7. Warehouse Management Systems

Selecting a WMS System

8. Inventory Record Accuracy

Physical Inventories

Cycle Counting

Error Reduction

9. Evaluating Warehouse Operations

Work Sampling

Time Standards


Warehouse Assessment

10. The Little Things

■ ■ ■ ■ ■ ■ ■

Value Stream & Process Mapping

The Strategos Guide To Value Stream and Process Mapping goes  beyond symbols and arrows. In over 163 pages it tells the reader how to do it and what to do with it.

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PUB FEB 2016