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Lean implementation case study for manual order picking and packing in warehousing operations

Naila Fares,Jaime Lloret,Vikas Kumar,G. Frederico,O. Kamach,J. Garza‐Reyes

Published 2025 in International Journal of Lean Six Sigma

ABSTRACT

Purpose This study aims to analyse the application of lean thinking in warehousing operations’ picking and packing processes. Design/methodology/approach The research design used is a conceptual framework based on the literature for lean practitioners’ guidance. Findings The results of the empirical study reveal an increase in efficiency of 30% in picking and packing operations when analysing and decreasing the non-value-added processes in this case study Research limitations/implications The proposed framework has not been implemented in a wide range of operations. The findings are limited due to the focused feature of the case study. Additional cost–benefit analysis can be investigated. Practical implications This study can guide warehousing logistics practitioners towards achieving excellence in manual picking and packing operations through lean thinking implementation. Originality/value This study overcomes the lack of a structured framework for lean manual order picking and packing and evaluates the potential of a set of lean and process analysis tools to increase the efficiency of order picking and packing.

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