Course: CI in Intralogistics

A 12-module practitioner course covering the full continuous improvement toolkit for warehouse and DC environments. Designed for operations supervisors, CI engineers, and DC managers who need to build, run, and sustain an improvement culture — not just run one-off events. By the end you’ll be able to diagnose a failing CI program, design a daily management system, run a structured kaizen event, and govern a multi-site CI function.

Modules

CI Program Foundation — what CI actually means in a warehouse; project vs. embedded CI; the 3 structural killers; 5-question field test
Lean Methods in DC Operations — TIMWOODS waste in DC context; VSM; Takt time; TPS pillars; TOC Drum-Buffer-Rope
Six Sigma DMAIC in DC — full mis-pick DMAIC worked example; Cpk math; SPC control charts; when to use DMAIC vs. kaizen
Structured Problem Solving — A3 template; 5 Whys (local vs. systemic fix); Fishbone (DC-adapted); FMEA (RPN = O×S×D); CAPA
5S and Visual Management — 5S phases; month 4–6 decay pattern and prevention; SQDC boards; andon systems
Standard Work Documentation — JBS format; work instructions; Skills Matrix; document lifecycle rules
Tier Huddle System — Tier 1–4 cadence; escalation logic; accountability-between-meetings fix; CAPA tracker connection
Kaizen Event Management — event charter; team selection; 5-day cadence; 6 required deliverables; 30/60/90 check-ins
Engineered Labor Standards — ELS lifecycle; coaching curve; gainshare design; True Value case study (71% productivity gain)
Warehouse Slotting CI — ABC math; slotting ROI (2–6 wk payback); re-slot triggers; look-alike adjacency defect mode
CI in Automated Facilities — 3 CI levers (manning/exceptions/software config); wave shaping; G2P port balancing; A/B testing
CI Program Governance — Hoshin Kanri X-Matrix; catchball; AOP integration; Shingo Model maturity; Belt pipeline