Lean Logistics Course

Lesson 1 • Origins and Principles of Lean

Traces lean from manufacturing roots to logistics contexts. Establishes the five lean principles as the analytical framework used throughout the course.

Lesson 2 • The Eight Wastes in Logistics

Defines and illustrates each waste category with logistics-specific examples. Provides the vocabulary needed for waste identification in later chapters.

Lesson 3 • Lean Culture and Continuous Improvement

Explains the behavioural and cultural conditions that sustain lean. Sets expectations for the mindset required to apply tools covered in subsequent chapters.

Lesson 1 • Building the Current State Map

Guides data collection and map construction for an existing logistics process. Accurate current state maps are the baseline for all improvement analysis.

Lesson 2 • Analysing the Current State

Applies lean metrics to reveal bottlenecks, excess inventory, and non-value-added steps. Analysis outputs directly inform future state design decisions.

Lesson 3 • Designing the Future State Map

Teaches principles for redesigning flow, pull, and pacemaker processes. Future state maps become the blueprint for lean implementation plans.

Lesson 1 • 5S Methodology Step by Step

Covers Sort, Set in Order, Shine, Standardise, and Sustain with logistics-specific applications. Sequential mastery of each step prevents common implementation failures.

Lesson 2 • Standard Work Documentation

Explains how to document repeatable logistics tasks to lock in best practices. Standard work is the foundation for training, auditing, and further improvement.

Lesson 3 • Sustaining 5S Through Audits

Provides audit design, scoring, and escalation frameworks for long-term 5S compliance. Regular audits convert one-time events into embedded operational discipline.

Lesson 1 • Kanban Design and Calculation

Teaches the formulas and variables used to size kanban loops for logistics replenishment. Correct sizing balances service levels against inventory investment.

Lesson 2 • Monitoring and Improving Pull Systems

Establishes metrics and review cycles to detect loop failures and adjust kanban quantities. Continuous monitoring ensures pull systems adapt to changing demand patterns.

Lesson 3 • Implementing Kanban in Warehouses

Covers physical set-up, supplier integration, and operator training for warehouse kanban. Practical implementation steps prevent the common pitfalls of poorly managed loops.

Lesson 1 • Warehouse Layout and Flow Design

Teaches spaghetti diagram analysis and lean layout principles for warehouse redesign. Improved layouts reduce travel distance and support continuous material flow.

Lesson 2 • Lean Order Picking Methods

Compares discrete, batch, zone, and wave picking for lean suitability. Selecting the right method eliminates motion waste and improves order accuracy.

Lesson 3 • Outbound Flow and Shipping Lean

Applies lean principles to packing, staging, and load planning processes. Smooth outbound flow prevents last-minute delays and carrier detention charges.

Lesson 4 • Lean Receiving and Inbound Flow

Analyses waste in receiving docks and inbound material handling. Streamlined receiving reduces lead time and prevents inventory accuracy errors downstream.

Lesson 1 • Milk Run and Route Optimisation

Explains milk run design for inbound and outbound freight consolidation. Optimised routes reduce cost per unit shipped and stabilise carrier schedules.

Lesson 2 • Carrier Collaboration and Lean Partnerships

Builds frameworks for sharing lean goals, data, and improvement projects with carriers. Collaborative relationships convert transactional vendors into lean partners.

Lesson 3 • Transportation Waste Identification

Applies the eight wastes framework specifically to freight and carrier operations. Identifying transport-specific waste is the prerequisite for network redesign.

Lesson 1 • Demand Levelling and Heijunka

Teaches heijunka box design and order smoothing to level production and logistics schedules. Levelled demand reduces the bullwhip effect and stabilises carrier and warehouse loads.

Lesson 2 • Integrated Information Flows

Maps information flows across supply chain tiers and identifies signal distortion points. Accurate, timely information is the nervous system of a lean supply chain.

Lesson 3 • Supplier Development for Lean

Covers supplier assessment, lean training deployment, and joint improvement projects. Lean suppliers reduce inbound variability that disrupts internal logistics operations.

Lesson 4 • End-to-End Lead Time Reduction

Applies total value stream analysis to compress lead time across all supply chain tiers. Shorter end-to-end lead time improves responsiveness and reduces finished goods inventory.

Lesson 1 • Lean Maturity Assessment and Roadmaps

Uses maturity models to benchmark current lean capability and prioritise future investments. Roadmaps translate assessment findings into sequenced, resource-aligned improvement plans.

Lesson 2 • Lean Logistics KPI Framework

Defines the key metrics for measuring waste, flow, quality, and delivery in logistics. A balanced KPI set prevents local optimisation at the expense of system performance.

Lesson 3 • A3 Problem Solving in Logistics

Applies the A3 structured problem-solving method to recurring logistics performance gaps. A3 thinking builds root-cause discipline and prevents symptom-only fixes.

Lesson 4 • Daily Management and Gemba Walks

Establishes structured daily management routines and gemba walk protocols for leaders. Consistent leader presence at the gemba accelerates problem detection and resolution.