What does it mean to have standardization in a warehouse?
Without sacrificing flexibility, standardization is a lean principle that ensures processes are easily repeatable, simple to train, and straightforward to improve upon. With less variation, less customization is required. And who customizes? People do; so standardization leads to better organization and reduced labor costs.
What areas of the warehouse can be standardized?
Standardization can be applied to:
- Unit loads or container sizes
- Equipment such as forklifts, pallet racking, and RF scanners
- Work processes and training
Look for a common theme in your warehouse operations. Apply the 80-20 rule to your current setup. Can you identify commonalities in what you’re already doing?
Standardize your unit loads
Do you receive loads of varying sizes? By investing time in repalletizing loads onto standard-sized pallets, could you ultimately reduce your handling costs? Perhaps this will allow the use of both pallet jacks and reach trucks, eliminating the need for forklifts with fork positioners. This can result in reduced training costs, easier rental sourcing, and lower equipment costs.
Standardize your equipment
By reducing the number of different brands of lift trucks in your operation, could you decrease:
- Training costs
- Maintenance expenses
- Equipment sourcing costs
Familiar controls between lift trucks can speed up cross-training of operators and may reduce the chance of accidents. This could also result in lower workers’ compensation insurance premiums.
By using stand-up counterbalanced forklifts instead of sit-down models, will this shorten the training time for operators transitioning from working with reach trucks in the aisles to counterbalanced forklifts on the dock?
Standardize your warehousing processes
Is there a warehouse worker with a more efficient method and higher productivity levels? By implementing this method across the entire team, you can ensure consistent productivity throughout your operation.
Once a baseline for productivity is established, new innovations can be identified and applied.
Your thoughts?
How have you implemented standardization in your warehouse operations? What has worked, and what hasn’t? Comment below.