Enhancing Industrial Logistics Efficiency Through Lean and Simulation

Abstract

This study presents an applied engineering approach to the reorganization and optimization of logistics operations in an industrial manufacturing environment. The research addresses inefficiencies identified in warehouse layout, internal transportation, production planning, and expedition processes within a construction materials facility. The primary objective was to enhance operational performance by reducing material handling waste, improving customer service levels, increasing safety conditions, and optimizing space utilization. A structured methodology was adopted, combining lean principles, inventory parameter revision, ABC classification, Kanban-based production control, layout redesign, and discrete-event simulation modeling. Time studies and value stream mapping were conducted to diagnose the current state and identify critical bottlenecks. Based on the findings, a new storage configuration organized by product rotation and production flow was implemented, along with standardized loading procedures and improved traffic circulation zones. A digital Kanban tool was developed to stabilize production planning and reduce variability in stock levels. To validate the proposed improvements, a simulation model was developed representing the current and redesigned systems. The results demonstrate a reduction of over 10 kilometers in daily forklift travel distance, nearly two hours of labor time saved per day, and a 28-second decrease in loading time per pallet. The findings confirm that integrating lean engineering practices with simulation technology enables measurable performance gains and supports data-driven decision-making in industrial logistics systems.