Signals worth examining
Stock is difficult to find, orders wait for picking and quantities are corrected manually. Similar symptoms can have different causes: incomplete transfers, incorrect product codes, unclear storage locations or delayed system updates. We start with a specific operation and its history.
Follow the goods
We identify who acts, when a record is created and what allows work to move forward. Exceptions matter as much as the normal flow: short deliveries, damaged goods, partial picks or returns without the original document.
- Receiving and quantity checks.
- Putaway and internal transfers.
- Reservations, picking and dispatch.
- Returns, quarantine and write-offs.
- Counts and discrepancy approval.
Applying Lean
We look for unnecessary movement, waiting, repeated checks and informal handovers. With the team, we assess whether a simpler sequence or clearer work location would help. We agree on changes within warehouse constraints and test them in a defined area.
Changes in ERP or WMS
The system needs to reflect the agreed operation: locations, units, statuses, reservations and user permissions. We identify existing configuration options, instructions that need updating and any integration or module requirements. A new WMS or new hardware is not automatically necessary.
Measuring the outcome
Before making changes, we select metrics and measurement methods: operation time, repeated picking, manual adjustments or discrepancies. We compare similar periods and workloads. Deliverables may include process maps, revised rules, system configuration and instructions; the exact scope is agreed at the start.