Lean Warehousing in FMCG Logistics: Measured Gains from Cycle Counting and 5S-Peruvian 3PL Case Study
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International Journal of Recent Engineering Science (IJRES) |  |
| © 2025 by IJRES Journal | ||
| Volume-12 Issue-4 |
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| Year of Publication : 2025 | ||
| Authors : Rafael Jesús Delgado-Montoya, Jair Henry Requena-Maceda, Wilson David Calderón-Gonzales |
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| DOI : 10.14445/23497157/IJRES-V12I4P105 |
How to Cite?
Rafael Jesús Delgado-Montoya, Jair Henry Requena-Maceda, Wilson David Calderón-Gonzales, "Lean Warehousing in FMCG Logistics: Measured Gains from Cycle Counting and 5S-Peruvian 3PL Case Study," International Journal of Recent Engineering Science, vol. 12, no. 4, pp. 50-62, 2025. Crossref, https://doi.org/10.14445/23497157/IJRES-V12I4P105
Abstract
The textile industry has long struggled with achieving high production efficiencies while simultaneously securing product quality, primarily owing to fragmented process controls and endemic inefficiencies. Previous literature has introduced isolated corrective measures, yet weaknesses in overarching workflow optimization persist. The present investigation sought to fill these voids by formulating and executing a holistic improvement framework that marries Lean Manufacturing principles with ergonomically informed workplace redesigns, thereby both rationalizing process flows and upgrading employee environments. Strategic interventions advanced by the study included the codification of process parameters, the iterative reconfiguration of workstations, and the refinement of inventory control methods. Quantitative appraisal revealed a 17-per cent uplift in throughput, a 12-per-cent decline in product defects, and a 20-per-cent contraction in waiting times, thereby corroborating substantial efficiency gains. These results highlight the framework’s dual capacity to fortify operational competitiveness and to enhance worker health. Scholarly contribution is attained by demonstrating a repeatable methodology suited to small and medium-sized enterprises. The study’s achievements invite ongoing investigation into the adaptation of such integrative frameworks for scalable, sustainable advancement across the textile sector.
Keywords
Lean Warehousing, Cycle Counting, 5S Methodology, Inventory Accuracy, Order Picking Efficiency, OTIF.
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