Professional events of the HALPIM congress

Lean logistics

"Let us find the gorillas"

It was the second time that lean topics were covered in a separate section at the annual HALPIM congress, once again with the sponsorship of E-Con Solutions. The short video clip - played at the beginning of the second day - drew the attention of all participants to the wastes, the "invisible gorillas" of everyday logistic processes.


Lean logistics simulation


As a light continuation of the Thursday evening banquet, a logistics simulation took place in the closing day of the congress. Although there were less participants then registered in advance - let us write this to the account of the successful banquet :-) - those who were present threw themselves enthusiastically into the operation of logistic processes. Lean consultants of E-Con Solutions developed the simulation specifically for this occasion. Through the simulation participants were able to experience the results of lean thinking in logistics.  The "fictional" - in fact based on the production and logistics processes of an existing company - process involved the following steps and positions:

  • commission of raw material stored at a third party warehouse,
  • truck deliveries,
  • internal warehouse material handling,
  • internal commission,
  • support of production,
  • administration,
  • production.


(6 pallet batch)
(One Piece Flow)
Finished goods produced 37 113
End time 20:00 15:13
Stock (WIP at 4 minutes) 61 50
Stock (WIP at 8 minutes) 56 50
Stock (WIP at 12 minutes) 67 45
Stock (WIP at 16 minutes) 72 44
Stock (WIP at 20 minutes) 76 -
Average stock 6647
Average area used 10071
Production downtime 13:24 2:53
Downtime % 67%19%



The goal of the simulation was to support production without any downtime.  It is visible from the results that the participants in the first round - with push system and batch operation - were able to build only half of the customer demands and had a significant production downtime (67%!), although they were working very hard.

After the first round they listed the possible wastes and determined the reserves in the processes, then the participants created the new process with: simplification, elimination of some of the steps completely, better teamwork, speed up and automation of information flow, and the usage of the theories „Pull system” and „One Piece Flow”.

There was only one constraint: there is no opportunity for investment, they have to develop the new process with the existing layout and tools, through the implementation of lean principles.

With the modifications the second round of the simulation was much better than the first one:


  • customer demands were met in full,Kirtkels
  • required production time decreased drastically,
  • the use of floor space was reduced,
  • inventory was more accurate,
  • the team found value-adding work for the members who's earlier positions were discontinued.

Last but not least production downtime - even if it was not eliminated completely - was reduced drastically to 19%. At the end of the simulation the participants collected besides good solutions also the still existing or newly emerged wastes as well - as additional reserves for continuous improvement - because "finding gorillas" cannot be stopped neither in the field of logistics!

Photos of the event can be viewed here!


Related lean tools:

Standard Work, Kanban6S, JIT, Lean logistics, Lean administration, Results


Strict Standards: Only variables should be assigned by reference in /home/econ/public_html/modules/mod_lofarticlesslideshow/helper.php on line 292
Special projects
Corvinus University
Publishing Lean Thinking
Process and organizational cultur assessment
E-Con Solutions
Folyamatfejlesztő és Tanácsadó Kft.

1119 Budapest, Bornemissza tér 12.
Tel.: +36 1 246-7193
Fax: +36 1 700-2599
This email address is being protected from spambots. You need JavaScript enabled to view it.