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Lean Warehousing and Distribution Operations: Gemba-Based Workshop (2 Day Class)

This highly interactive two-day workshop is for people responsible for implementing lean principles in a distribution center operation.

The workshop combines lecture, gemba (on-site)  experience, group discussion, participative simulations, and group exercises to reveal the key steps for implementing lean principles in a traditional distribution operation. You’ll learn how the application of lean principles improves the efficiency, quality, safety, and space utilization of a distribution center.


During the workshop, you’ll create an experiential learning environment through a series of rapid plan-do-check-act cycles to understand the phases and steps needed to improve service, costs, and create a problem-solving environment for continuous improvement.

Progressing through our three-round simulation, you will identify changes, implement them, and measure the impact of applying lean tools and principles to distribution processes.

Round 1: reflects a conventional distribution center and its impact on customers, associates and management
Round 2: reflects a distribution center after a lean benchmarking trip taken by management
Round 3: will reflect an operation after lean storage techniques and processes have been implemented

Both traditional and lean operating systems are evaluated and compared for on-time deliveries, lead time, quality, efficiency, space usage, equipment utilization, and cost per shipping line.

You will learn the key steps for applying lean principles to transform a traditional warehouse operation. Hands-on participation in a simulation will teach you how to apply the principles and tools so you can repeat the application in your environment. Companies applying these principles, components, steps, and tools have experienced operational improvements in reduced internal damage and injuries along with improved storage and operational efficiencies of 15% to 30%.

"I was familiar with the concepts and tools introduced in class, and had even implemented some of them … However, the Warehousing course still introduced me to new ideas and material that I wish I would've had in my knowledge-bank prior to the facility launch. This gemba-based workshop is a very good, high-level type training on how to implement Lean principles (level flow, small batch sizes, quality at the source, standard work) into a warehousing environment, and the exercises and gemba walk of a facility made it possible to see these principles and tools in practice. Also, the instructors were passionate about the material and have experience in the field, which makes the workshop a lot more enjoyable"

-Ana Bailey, Supply Chain Engineer

Course Outline:

Day One

  • Lean Warehouse Overview
  • Simulation/Round 1: Traditional
  • Lean Storage Implementation:
    • Detail review of 5 Phases
    • Team Exercise: Storage planning and downsizing
  • Simulation Round 2: Operation after Lean Benchmarking
  • Gemba Walk and Benchmarking- CITY Furniture Distribution Center

 Day Two

  • Just In Time Implementation:
    • Detail review of 5 Phases
    • Team Exercises: Cycle Times, Operations Diagram, Workload Planning, Progress Boards
  • Simulation/Round 3: Lean Warehouse Operation
  • CITY Furniture Leadership Team Q & A
  • Summary

Who Should Attend:
All levels of management from vice-president to supervisor, change agents, professional staff, and hourly associates  from organizations at any stage of a lean journey.

Health and Safety Information:

Please see this page to review our health and safety precautions for this workshop.



Workshop Suggestions:
To maximize your learning experience we recommend that prior to attending this program you take following workshops or have a good understanding of the concepts presented within them.
Suggested Reading for this Workshop:
Locations and Dates for Lean Warehousing and Distribution Operations: Gemba-Based Workshop

No offerings of this workshop are scheduled at this time. Please check back again soon.

Price: $1,600.00 ($1,400.00 if the participant is taking 2 or more workshops at one location)
Price includes all participant materials, breakfast, lunch and snacks each day

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Cancelation Policy
Our workshops are designed to cater to a limited number of participants.  If you must cancel a workshop registration, you will be given a full refund up to four weeks before the workshop.  A cancelation occuring within four weeks of the workshop will be subjected to a $350 cancelation fee.  If cancellation is required to comply with coronavirus guidelines from federal, state, or local authorities, no cancellation fee will apply.  LEI will not be held personally responsible for any incidental cost incurred (hotel, airfare, change fee, etc).  To cancel a workshop registration, please call LEI at (617) 871-2900.