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            September 17, 2025 | Plymouth, WI

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Lean Events and Training / Events / Lean Warehousing and Distribution Operations

Lean Warehousing and Distribution Operations

Improve a distribution center's efficiency, quality, safety, and space utilization.

Dates

Toro in Plymouth, WI
September 17, 2025 - September 18, 2025: 8:00am - 4:00pm CT

Location

Plymouth, WI

Why you should attend

Learn how applying lean principles can improve a distribution center's efficiency, quality, safety, and space utilization.

Cost

$1,599 Early bird price*
$1,999 Regular price

*Early bird expires August 22, 2025.

Lean Warehousing and Distribution Operations

Register
  • Overview
  • Agenda
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In this highly interactive two-day workshop, lectures, gemba (on-site) experiences, group discussions, participative simulations, and group exercises reveal the key steps for implementing lean principles in a traditional distribution operation. You’ll learn how applying lean principles improves a distribution center’s efficiency, quality, safety, and space utilization.

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

Progressing through a 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

You will evaluate and compare traditional and lean operating systems for on-time delivery, lead time, quality, efficiency, space usage, equipment utilization, and cost per shipping line.

This hands-on learning experience will teach you the key steps for applying lean principles to transform a traditional warehouse operation, including 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%.

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.

Discounts

  • Register three or more students from your organization and save 12.5% off every registration. To receive a group discount, register as a group through the registration link and the discount will automatically apply.
  • LEI Co-Learning Partners: Register before early bird deadline for $1,199.25. Register after early bird deadline for $1,499.25. No group discount can be applied.

Cancellation Policy

You can cancel your registration for in-person workshops four weeks before the course’s start date for a full refund. A cancellation occurring within four weeks of the workshop dates will be subject to a $350 fee. Cancelling less than two weeks prior to workshop start is subject to no refund. To cancel, please call LEI at (617) 871-2900 or email registrar@lean.org.

Course Outline:

Day 1: 8:00 am – 4:30 pm
Lean Warehouse Overview
Simulation Round 1: Traditional
Lean Storage Implementation:
  • Phases 1 & 2
  • Simulation Round 2: Operation after Lean Benchmarking
    Lean Storage Implementation:
  • Phases 3 & 4
  • Gemba Walk and Benchmarking- Warehouse Visit
    Storage Exercise Debrief and Lean Storage Phase 5
    Summary and Wrap-up
    Day 2: 8:00 am – 4:00 pm
    Just In Time Implementation:
  • Phases 1-3
  • Exercise – Standards and Cycles Plus Standard Work
    Just In Time Implementation:
  • Phase 3-Standard Work and Operations Diagram
  • Exercise – Operations Diagram
    Just In Time Implementation:
  • Phase 3-Workload Planning
  • Exercise – Workload Planning
    Just In Time Implementation:
  • Phase 3-Progress Boards
  • Exercise – Progress Boards
    Just In Time Implementation:
  • Phase 3-Phase 3 Managers Role
  • Simulation Round 3: Traditional
    Team Q & A
    Summary
    Luis Quinoes

    Luis Quinones

    Senior Manager and Lean Coach,
    Lean Quest, LLC

    Luis has over 16 years of experience in the warehousing and distribution industry, with 14 focusing on Lean Implementation. His lean journey started at Toyota’s North American Parts Operations Division, where he spent six years in the network’s largest Parts Distribution Center and the planning and launch of both National Parts Centers. He dedicated his […]

    Read more about Luis Quinones

    Address:

    Toro Co
    3424 County Rd PP,
    Plymouth, WI 53073

    Suggested Nearby Hotels:

    • Fairfield Inn & Suites Sheboygan
      4117 South Taylor Drive, Sheboygan, WI 53081
      This hotel is located approximately 12 miles from Toro (~18 minute drive). 
    • Home2 Suites by Hilton Sheboygan
      3960 N Marquette Circle, Sheboygan, WI 53083
      This hotel is located approximately 14 miles from Toro (~17 minute drive). 
    • Holiday Inn Express & Suites: Sheboygan-Kohler (1-43)
      3823 Germaine Avenue, Sheboygan, WI 53081
      This hotel is located approximately 12 miles from Toro (~18 minute drive). 

    Nearest Airports:

    Milwaukee Mitchell International Airport (MKE) ~56 miles to Plymouth, WI
    Green Bay Austin Straubel Int’l Airport (GRB) ~65 miles to Plymouth, WI

    Bring Our Practical, How-to Training to Your Company

    Custom Training

    “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

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