Logistics Lean Case Study Dark

An Operational Excellence Training Program Delivers $4M in Costs Savings


A global Lean Training Program has reached over 270 people worldwide and driven $4M+ in cost savings through project delivery and online mentoring & coaching. Our approach included a tailored, highly interactive 2,5-day training program covering the core lean topics to open new ways of thinking to drive improvement activities.

> With over 270+ people trained across 5 continents (some via virtual sessions), over $4M has been signed off as part of the training and mentoring program.

In 2019, we launched a global Operational Excellence Training Program for DeliveryCo* based in the Middle East. The goal of the program was to combine education, learning and real-life projects to deliver process efficiencies, cost optimisation and develop best practice sharing across this global Express Delivery and Logistics company.

The project was multi-phased.

Phase 1 was a holistic approach taken to train a large number of people and through project mentoring and coaching, drive sustainable projects with real return on Investment. We designed and personalised a 2.5 day Lean focused training course and trained over 240 candidates from 23 countries. The total benefits so far is $3.5M with a second Phase 1 round planned for late 2021.

Phase 2 focused on more executive leadership training and building future talent within the company. Candidates who successfully delivered a real-world project were invited to take a Lean Six Sigma Green Belt course. Once again, this was a mixture between a 3.5-day training course, monthly webinars and project coaching and mentoring. We have trained 37 people and the project benefits from their projects will be $0.5M so far with an estimated $2M to follow in 2021.

Phase 3 – which is planned for 2021/2022, is to take the top 10 to 15 candidates and deliver a Lean Six Sigma Black Belt training course so they are ready to drive corporate-wide change projects and prepare for new leadership roles within the company.

[Over $4M has been delivered in quantifiable hard cost savings across the business. The teams have been working directly with their finance business partners to quantify and sign off all reported savings.

The training has now covered 270 people globally covering the Middle East, North and Southern Africa, Asia, Australia & New Zealand plus Europe and America (2021).

The program today has delivered over 3000% Return on Investment. Combining training with real-world projects, mentoring and coaching make learning an investment decision, not a cost.

With fast growth, comes fast change and often it is required to consolidate our processes to simplify what we do. In this example, DeliverCo had grown and expanded very fast but was under increasing pressure from new entrants within the Express Delivery and Logistics space. The goal of this program was to upskill large numbers across the workforce but also to optimise and improve local and global processes.

The training program was “project-focused” with the goal of each session was to teach, prepare and identify improvement opportunities across the operations. With every session we ran, we wanted to have a direct impact and support cost optimisation across the business. Through careful planning, we created a unique action-focused workshop that took the lean tools and turned them into practical exercises and real-life examples.

Along with the training, we provide project reviews, coaching and mentoring to support both the client’s internal team but each an every candidate when required. This hands-on approach ensured that projects were delivered in alignment with the business strategy and also learnings could be shared across the entire group, driving improved global collaboration.

*We take our client’s confidentiality serious. While we’ve changed their names, the results are real.”

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Reagan Pannell

Reagan Pannell

Reagan Pannell is a highly accomplished professional with 15 years of experience in building lean management programs for corporate companies. With his expertise in strategy execution, he has established himself as a trusted advisor for numerous organisations seeking to improve their operational efficiency.

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