Assessing lean warehousing: Development and validation of a lean assessment tool a doctoral dissertation

Abstract

Scope and Method of Study:

This research was undertaken to fill a gap in the academic literature and in practice by developing a comprehensive lean implementation assessment tool for warehousing operations implementing lean manufacturing principles and techniques. Furthermore, the results from the application of the lean implementation assessment tool are analyzed to better understand the practical implementation and underlying factors of lean warehousing. Consequently, the research outcomes are two-fold, both filling the gap in the development of a comprehensive warehousing lean implementation assessment tool and providing insight into the actual implementation of lean warehousing.

Findings and Conclusions:

The eight lean constructs that are measured in the lean implementation assessment tool developed in this research are visual management, standardized processes, continuous and leveled flow, pull systems, workplace organization, empowered employees, quality assurance, and continuous improvement. The lean constructs were operationally defined with respect to the associated lean practices to measure implementation and utilization on various evaluations points comprising the various warehousing processes in a facility. From the Factor Analysis, the seventeen significant factors observed in the data measuring lean warehousing related to continuous improvement and problem solving, building in quality, pull systems, standardized processes, customer integration, quality assurance, people, inventory management, material flow, information sharing, point of use storage, inventory strategy, employee development, workplace organization, employee retention, quality systems, and first in first out.