1) Maintain a Comprehensive Process Log of All Changes
While it is typical for warehouse managers to monitor inventory error rates,
many of them fail to utilise the information contained within these data. While
mistake rates undoubtedly indicate difficulties, they are most useful when seen
as signs of systemic flaws inside an organisation.
The simplest method to discover these failure points is to meticulously record
any changes in training procedures, new employees, newly introduced technology,
or other warehouse-related changes. When examining mistake rates, the
distinction between proactive and reactive decision-making is the ability to
quantify these changes over time.
2) Focus on processes that bolster accountability
When implementing a procedure or process in your warehouse, the benefits of
these strategies are nullified when employees circumvent the system or devise
workarounds. Too frequently, a mistake made at the beginning of the choosing
process is not a major concern for the culprit, who knows that someone further
down the line, most likely a packer, would address the issue.
Create a system within your organisation that not only fosters accountability,
but also emphasises the significance of precision. For instance, design a
location for packers to deposit incorrect goods and instruct them to tell
pickers rather than correcting the error themselves. Long-term gains in
productivity will result from employees who pay closer attention to the
3) Offer your employees Continuing Education Courses
It is essential to invest in technology that enables employees to perform
their duties properly. It is equally essential to invest in their development.
By doing so, you may establish a “lean” culture and workforce that
can collaborate to continuously enhance the operation.
LeanCor, for instance, has had tremendous success with the custom crating and
logistics Academy. The Academy educates employees on lean manufacturing
concepts such as FIFO, PDCA, and other concepts consistent with lean
manufacturing and supply chain management as part of an optional programme.
While participation is voluntary,custom crating and logistics employees have
shown outstanding enthusiasm in the programme. The majority of team members
have finished study for Level 1, and many will begin Level 2 coursework this
The results of the custom crating and logistics
procedure have likewise been
excellent. Since introducing the Academy, LeanrCor has been able to exceed
monthly targets while continuing to improve year-round. In addition to enhancing
customer performance, the academy has greatly improved custom crating and
logistics’s culture and fostered an atmosphere of learning and leadership
throughout its ranks.
4) Exhibit Leadership in the Arena
No matter how hard you work to streamline the warehouse, redundancies and
superfluous processes will emerge over time. It is the nature of the animal.
And the repetitious nature of many warehouse duties makes it not only difficult
to cure these habits, but also difficult to identify them before they become a
A member of your organization’s leadership can assist in identifying these
patterns by simply traversing the warehouse floor, or visiting the gemba. When
doing so, ask your leaders to challenge “why” rather than
“how” things are being done. Having eyes that aren’t immersed in the
day-to-day is an effective method for uncovering odd activities.
According to a poll, distribution centre managers are aware that their
warehouses are not fully optimised, but they lack the time, money, and
strategies necessary to significantly enhance operations.
The report indicated that mid-sized warehouses (about 50 employees) lose nearly
3,000 hours per year due to workforce inefficiency. Moreover, while 89 percent
of those polled believed that new technology may assist warehouse managers in
recouping these inefficiencies, just 70 percent had performed a comprehensive
evaluation of warehouse processes within the preceding year.
In this article, we will outline four methods for evaluating your warehouse
operations and eliminating unnecessary, inefficient procedures.