• Vol 9, No 1 (2018)
  • Industrial Engineering

Implementation of Lean Principles to Improve the Operations of a Sales Warehouse in the Manufacturing Industry

Bibin Baby, Prasanth N, D. Selwyn Jebadurai


Publish at : 27 Jan 2018 - 00:00
IJtech : IJtech Vol 9, No 1 (2018)
DOI : https://doi.org/10.14716/ijtech.v9i1.1161

Cite this article as:
Baby, B., N, P., Jebadurai, D.S., 2018. Implementation of Lean Principles to Improve the Operations of a Sales Warehouse in the Manufacturing Industry. International Journal of Technology. Volume 9(1), pp.46-54
78
Downloads
Bibin Baby SRM Institute of Science and Technology
Prasanth N SRM Institute of Science and Technology
D. Selwyn Jebadurai SRM Institute of Science and Technology
Email to Corresponding Author

Abstract
image

This paper deals with the implementation of lean techniques in a sales warehouse in the manufacturing industry. It highlights efforts to improve warehouse operations by eliminating waste using lean tools such as a value stream map (VSM). A current state VSM exposes waste in an existing system. High order picking time, improper storage, delay in vehicle loading, and low space utilization make the warehouse inefficient. Implementation of a U-shaped flow layout in the warehouse improves order picking time, vehicle loading time, and space utilization. A future state VSM shows the new state of operations before implementation. After lean implementation, considerable improvements were observed in vehicle loading, space utilization, and storage. Thus, the efficiency of warehouse operations is increased, resulting in quicker responses to customers’ demands.

ABC analysis; Layout; Lean manufacturing; Value stream mapping; Warehouse

Introduction


References

Abdulmalek, F.A., Rajgopal, J., 2007. Analyzing the Benefits of Lean Manufacturing and Value Stream Mapping Via Simulation: A Process Sector Case Study. International Journal of Production Economics, Volume 107(1), pp. 223–236

Arslankaya, S., Atay, H., 2015. Maintenance Management and Lean Manufacturing Practices in a Firm Which Produces Dairy Products. Procedia-Social and Behavioural Sciences, Volume 207, pp. 214–224

Bortolini, M., Faccio, M., Gamberi, M., Manzini, R., 2015. Diagonal Cross Aisles in Unit Load Warehouses to Increase Handling Performance. International Journal of Production Economics, Volume 170 Part C, pp. 838–849

Chiabert, P., Antonio, G.D., Inoyatkhodjaev, J., Lombardi, F., Ruffa, S., 2015. Improvement of Powertrain Mechatronic Systems for Lean Automotive Manufacturing. Procedia CIRP, Volume 33, pp. 53–58

Dotoli, M., Epicoco, N., Falagario, M., Costantino, N., Turchiano, B., 2015. An Integrated Approach for Warehouse Analysis and Optimization: A Case Study. Computers in Industry, Volume 70, pp. 56–69

Fullerton, R.R., Kennedy, F.A., Widener, S.K., 2014. Lean Manufacturing and Firm Performance: The Incremental Contribution of Lean Management Practices. Journal of Operations Management, Volume 32(7-8), pp. 414–428

Jiménez, M., Romero, L., Dominguez, M., del Mar Espinosa, M., 2015. 5S Methodology Implementation in the Laboratories of an Industrial Engineering University School. Safety Science, Volume 78, pp. 163–172

Khamis, N., Abrahman, M.N., Jamaludin, K.R., Ismail, A.R., Ghani, J.A., Zulkifli, R., 2009. Development of 5S Practice Checklist for Manufacturing Industry. World Congress on Engineering, Volume 1, pp. 978–988

Rohac, T., Janusuka, M., 2015. Value Stream Mapping a Real Case Study. Procedia Engineering, Volume 100, pp. 520–529

Rohani, J.M., Zahraee, S.M., 2015. Production Line Analysis via Value Stream Mapping: A Lean Manufacturing Process of Color Industry. Procedia Manufacturing, Volume 2, pp. 6–10

Suhadak, N.S., Amit, N., 2015. Facility Layout for SME Food Industry via Value Stream Mapping and Simulation.  Procedia Economics and Finance, Volume 31, pp. 797–802

Tyagi, S., Choudhary, A., Cai, X., Yang, K., 2015. Value Stream Mapping to Reduce the Lead-time of a Product Development Process. International Journal of Production Economics, Volume 160, pp. 202–212

Van den Berg, J.P., Zijm, W.H.M., 1999. Models for Warehouse Management: Classification and Examples. International Journal of Production Economics, Volume 59(1-3), pp. 519–528

Venkataraman, K., Vijaya Ramnath, B., Muthu Kumar, V., Elanchezhian, C., 2014. Application of Value Stream Mapping for Reduction of Cycle Time in a Machining Process. Procedia Materials Science, Volume 6, pp. 1187–1196

Yang, T., Kuo, Y., Su, C.-T., Hou, C.-L., 2015.  Lean Production System Design for Fishing Net Manufacturing using Lean Principles and Simulation Optimization. Journal of Manufacturing Systems, Volume 34, pp. 66–73