Lean implementation case study for manual order picking and packing in warehousing operations

Fares, Naila and Lloret, Jaime and Kumar, Vikas and Frederico, Guilherme Francisco and Kamach, Oulaid and Garza-Reyes, Jose Arturo (2025) Lean implementation case study for manual order picking and packing in warehousing operations. International Journal of Lean Six Sigma. ISSN 2040-4166

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Abstract

Purpose
This study aims to analyse the application of lean thinking in warehousing operations’ picking and packing processes.

Design/methodology/approach
The research design used is a conceptual framework based on the literature for lean practitioners’ guidance.

Findings
The results of the empirical study reveal an increase in efficiency of 30% in picking and packing operations when analysing and decreasing the non-value-added processes in this case study

Research limitations/implications
The proposed framework has not been implemented in a wide range of operations. The findings are limited due to the focused feature of the case study. Additional cost–benefit analysis can be investigated.

Practical implications
This study can guide warehousing logistics practitioners towards achieving excellence in manual picking and packing operations through lean thinking implementation.

Originality/value
This study overcomes the lack of a structured framework for lean manual order picking and packing and evaluates the potential of a set of lean and process analysis tools to increase the efficiency of order picking and packing.

Item Type:	Article
Identification Number:	10.1108/IJLSS-05-2024-0097
Dates:	Date Event 3 February 2025 Accepted 20 March 2025 Published Online
Uncontrolled Keywords:	lean, order picking, order packing, manual process, warehouse, framework
Subjects:	CAH17 - business and management > CAH17-01 - business and management > CAH17-01-02 - business studies
Divisions:	Faculty of Business, Law and Social Sciences > College of Business, Digital Transformation & Entrepreneurship
Depositing User:	Gemma Tonks
Date Deposited:	25 Mar 2025 12:51
Last Modified:	25 Mar 2025 12:51
URI:	https://www.open-access.bcu.ac.uk/id/eprint/16260

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