LeanLagerung

LeanLagerung is a set of methods for applying lean manufacturing principles to warehousing and storage operations with the aim of minimizing waste, reducing inventory levels, and improving flow and accuracy throughout the supply chain. It emphasizes standardized processes, visual management, and continuous improvement, and is often implemented as part of broader lean or TPS transformations.

Key principles include mapping the warehouse value stream to identify non-value-adding activities, eliminating the seven wastes (overproduction, waiting, transport, unnecessary motion, inventory, defects, and underutilized talent), and implementing pull-based replenishment. Techniques commonly used are 5S, standardized work, slotting optimization, zone or batch picking with deterministic layouts, cross-docking, and Kanban or signal-based restocking. Digital tools such as warehouse management systems and real-time data analytics support demand-driven operations, cycle counting, and accurate inventory records. Practices like poka-yoke (error-proofing) and visual controls help reduce errors and speed decision-making.

Benefits of LeanLagerung include lower holding costs, reduced storage footprint, faster order fulfillment, higher picking accuracy, safer and more ergonomic working conditions, and improved inventory turnover. Typical performance indicators cover inventory turns, fill rate, order cycle time, dock-to-dispatch time, picking accuracy, and space utilization.

Implementation generally proceeds from a current-state map to a future-state design, followed by pilot implementation, standardization, and scale-up. Critical success factors include strong management support, cross-functional teamwork, reliable data, staff training, and a phased rollout to manage change and mitigate stockouts during transition.