Model to Improve Order Cycle Time in a Mass Consumption Company Using Lean Warehousing 4.0

Lean Warehousing is a lean methodology focused on improving distribution center processes by reducing or eliminating waste that does not generate value. This article addresses the issue of order cycle time delays, a critical challenge in distribution center management that can significantly impact operational efficiency and customer satisfaction. Through the application of Lean Warehousing, the aim is to reduce order cycle time to improve fulfillment levels. This study is based on a systematic analysis and demonstrates how Lean methodologies can be successfully applied in a retail storage environment. The proposed model employs tools such as standardized work, error prevention (Poka Yoke), and the 5S methodology, in conjunction with path planning and picking strategies. By applying simulation, the results show a significant reduction in cycle times during the stages of receiving, processing, picking & packing, delivery, and order closing, with improvements ranging from 13% to 19%, a 27% increase in the number of complete orders, and a 53% reduction in incomplete orders. These results highlight the potential of Lean Warehousing to transform storage operations, enhancing the efficiency and effectiveness of the order fulfillment process in a mass consumption company.