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

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.