Proposing a new framework for lean warehousing: first experimental validations

Lean principles have been increasingly adopted in manufacturing over the last decades and they have just recently spread their applicability to supply chains. In such a context, lean warehousing plays a significant role in order to achieve lower costs of logistics operations and increase flexibility and efficiency in pull supply chains driven by customer demand. However, both academic and professional literature is still poor and lacks structured methodologies and case studies integrating different lean techniques to optimize warehouse processes. This paper proposes a novel lean warehousing framework combining three well-known lean tools and presents the first outcomes of its validation campaign. In particular, it discusses the framework application to a raw material and component warehouse of an international company in the automotive sector. Results show that time savings up to 36% might be achieved in receiving, put away, and picking operations, bringing significant economic benefits in terms of labour, service level, and warehouse space. This study provides researchers with new opportunities for fostering continuous improvement in warehouse operations, while practitioners might benefit from it as a basis for evaluating and re-engineering warehouse processes towards lean principles. Future research will further validate and progress the lean warehousing framework.