Lean warehousing framework: Enhancing order fulfilment in food and beverage depots

Abstract

This study aims to develop and validate an integrated lean warehousing framework to enhance order fulfilment performance in Malaysian food and beverage depots. The method used was an explanatory sequential mixed design, with quantitative data collection from 207 respondents across 15 selected depots, and a qualitative time study through observation of the warehousing process. Principal Component Factor Analysis (PCA) identified six operational components, revealing significant performance differences between inbound and outbound operations: outbound operations are well-performed, with 75-80% satisfaction, whereas inbound operations experienced critical bottlenecks, with 40-51% satisfaction. Correlation analysis revealed 3 significant factors that caused warehousing inefficiency and affected order fulfilment: information inaccuracy due to inadequate computerized systems, lack of designated storage areas, and inappropriate packaging specifications. Based on the results, this study proposed a lean framework that strategically integrates Standardised Work, E-Kanban system, and ABC analysis to eliminate the identified waste. The implementation has resulted in a 45.9% reduction in operational time, improving from 3,339 minutes before intervention to 1,806 minutes after the lean implementation, achieving under 2 days of customer delivery expectations. This study theoretically contributes to the lean integration framework specific to food and beverage depots by providing evidence-based methodology for managers to improve operational efficiency and order fulfilment performance.