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Description

Lean Logistics: Mapping Flows, Reducing Stock and Improving Reliability

Applying lean methods to physical flows from the warehouse floor to the shipping dock

  • 2 days — 14 h
  • In-person or virtual
  • Intermediate
  • Up to 6 participants

The warehouse is running, yet stock levels keep climbing. Pickers walk more than they pick. Trucks wait at the dock while urgent orders jump the queue. Stock-outs are resolved through emergency shipments whose cost is never set against the supposed benefit of safety stock.

These two days apply lean to physical flows rather than to administrative processes. Participants map a logistics chain from goods-in to dispatch, measure lead times and distances travelled, size stock levels against observed demand, and lead improvement projects with warehouse operations teams.

Learning objectives

  • Map a physical flow from goods-in to dispatch
  • Measure lead times and picking distances
  • Identify the forms of waste specific to warehouse and transport operations
  • Size stock levels based on demand and its variability
  • Set up replenishment pulled by actual consumption
  • Lead an improvement project with operations teams

What makes this programme different

Picking layouts are reworked on an actual warehouse floor plan
The cost of emergency shipments is compared with safety stock levels
Proposed improvement projects are costed before being presented to management

Programme

1The logistics flow seen as a whole

Looking at the chain rather than at individual stations

  • Lean principles applied to physical flows
  • Mapping the chain from goods-in to dispatch
  • Measuring lead time and work in progress
  • Forms of waste in warehousing and transport

2Warehouse and operations

Reducing movement and rework

  • Zone layout and location addressing logic
  • Picking organisation and travel distance reduction
  • Scheduling of picking waves
  • Workstation discipline and housekeeping of zones
  • Inventory accuracy and handling of stock discrepancies

3Stock and replenishment

Letting demand pull the flow

  • Analysis of demand and its variability
  • Sizing safety stock and reorder points
  • Pull replenishment and replenishment loops
  • Levelling inbound receipts and supplier delivery slots
  • Handling slow-moving item references

4Performance management and continuous improvement

Sustaining performance over time

  • Selecting service and productivity indicators
  • Visual management in operational zones
  • Leading an improvement project on the floor
  • Working with carriers and measuring on-time performance
  • Costing and tracking the gains achieved

Who is it for

Logistics managers and warehouse team leaders, as well as supply planners and supply chain managers.

Prerequisites

Working in a logistics role and familiar with warehouse operations

Dates & locations

36 scheduled dates between November 2026 and December 2027. Seats are confirmed in the order enquiries are received.

November 2026

December 2026

January 2027

February 2027

March 2027

April 2027

May 2027

June 2027

September 2027

October 2027

November 2027

December 2027

None of these dates suit you? We open additional sessions on request, and any programme can be run privately for your team.

Practical details

Before the programme
Online positioning questionnaire. Your development objectives are shared with the trainer, who tailors the practical case studies to your context.
Teaching methods
Theoretical input, workshops and practical case studies. Digital course materials and method sheets provided.
Assessment
Multiple-choice tests and role-play exercises. Assessment of learning at the start and end of the programme, with immediate and 60-day follow-up evaluations.
After the programme
One year of access to the e-learning platform. Self-assessment of the skills acquired and a 30-day follow-up session with your trainer.
How to register
Registration online or on the basis of a quotation.
Lead time
11 working days after confirmation of registration.
Accessibility
Accessible to people of determination. Contact our accessibility coordinator to design a suitable solution: contact@mpf-academy.ae
Start dates
Rolling intake: in addition to the scheduled sessions, this programme can start on request.