The Effectiveness of Lean Warehousing Towards Reducing Waste in Manufacturing Companies Using Siemens Tecnomatix Plant Simulation Software (STPSS)

Originally developed for Toyota’s assembly line and vehicle manufacturing, lean manufacturing has become a widely adopted approach across various industries. However, most existing research primarily focuses on its application to production lines, often overlooking the unique challenges and opportunities within warehouse operations. Despite the crucial role warehouses play in the supply chain, there is a significant gap in the literature addressing the tailored application of lean methodologies in warehouse settings. This research aims to investigate the impact of implementing lean principles on warehouse processes in manufacturing companies, using Siemens Tecnomatix Plant Simulation Software (STPSS) for analysis. The study also seeks to evaluate the effectiveness of lean manufacturing tools in reducing waste and enhancing operational efficiency. A manufacturing company in Johor serves as the focal point for this research, aiming to guide the company towards lean warehousing. STPSS is employed as the primary method for this research, offering a 3D simulation model to visualize and analyse the proposed improvements. The outcomes of the simulation provide a comprehensive overview of the enhanced process flow layout. This study managed to reduce 30% of production time. These results clearly illustrate the positive impact of the modified layout on overall operations, emphasizing the effectiveness of the implemented changes.