Driving Efficiency with 5S: Noah Atkinson’s Summer Project

At CLG, we believe internships are more than just learning opportunities—we believe that they’re a chance to make a real impact. This summer, Logistics Engineering Intern Noah Atkinson did just that by taking on a key improvement project in our warehouse. 

Noah took on the challenge of redesigning our Parcel/LTL Packing Area, a space critical to warehouse operations. His goal was simple yet powerful: to make the area more efficient, standardized, sustainable, and user-friendly. By applying Lean Six Sigma principles and the 5S methodology, Noah delivered a redesign that not only improved efficiency but also set the foundation for lasting change.

Understanding the Challenge

The original layout of the packing area had several sources of waste:

• Long path lengths for warehouse employees.
• Boxes and materials weren’t stored strategically.
• Double handling due to layout constraints.
• Tools and supplies lacked standardization and organization.

These inefficiencies added up, costing valuable time and effort on every order.

Original layout shown in images above.

The Approach: Lean Six Sigma and 5S

Noah applied Lean Six Sigma principles and the 5S methodology (sort, set, shine, standardize, sustain). His use of the DMAIC framework maximizes this approach.

His process included:

• Spaghetti diagram analysis to map worker and driver movements.
• Process modelling and simulations for testing design improvements.
• Layout redesigns that engaged packing staff for feedback and testing.
• Standardization SOP and 5S Audit Program creation to ensure sustainability of improvements.

He also analyzed forklift safe speeds, studied warehouse temperature trends, and even built a Parcel Consolidation Savings Calculator to measure cost savings.

Redesigned layout plan shown above.

The Redesign in Action

Noah’s redesigned workstation included:

• Rubber-matted packing tables for improved product handling.
• Shadow boards for tools and SOPs to streamline changeovers.
• Optimized box and part storage systems under and around tables.
• Mounted foam rollers with kanban restocking system based on consumption rates and lead times.

These changes created a more organized, safer, and efficient environment for daily operations.

New Parcel/LTL Packing Area shown above.

The Redesign in Action

The improvements delivered clear benefits:

• Estimated 3 hours of time saved every week
• Reduced worker movement and time spent searching for materials.
• Increased consistency and quality across packing operations.
• A standardized framework for applying 5S improvements to other warehouse areas.

Noah’s work also provided long-term tools for sustainability, including SOP updates, monthly audits, and measurable savings through his consolidation calculator.

Looking Forward

The success of this project demonstrates how thoughtful process redesign can transform everyday operations. Noah’s approach and results set the stage for expanding these methods across other workstations and warehouses at CLG, driving efficiency and consistency company wide. 

Coastal Logistics Group (CLG) is a leading provider of comprehensive supply chain solutions, specializing in warehousing, transportation, and niche logistics services. With strategic hubs in Savannah, Charleston, and Norfolk, CLG offers unparalleled access to America's largest and fastest-growing ports. Services include advanced drayage, efficient distribution, and nationwide transportation, tailored for complex freight and on-site logistics. We creatively engineer and deliver seamless, systematic, and speedy solutions that drive business forward. For more information, please explore our website or request a quote.