Warehousing is an essential part of manufacturing supply chains, especially in high-volume product settings. Here, the accuracy of outbound dispatch directly impacts customer satisfaction and operational costs. This study uses a simulation based Lean Six Sigma DMAIC approach to examine and improve the outbound warehouse dispatch process for a tissue manufacturing company in the Philippines. The researcher analyzed historical dispatch records, conducted direct observations, and conducted interviews to find the root causes of delivery errors. The results showed that manual loading activities and the lack of real-time verification were the main causes of dispatch mistakes, leading to significant financial losses. The researcher designed and evaluated a digital dispatch verification system that uses barcode scanning and structured loading controls through simulation modeling. The simulation results show an 82.35% decrease in dispatch discrepancies and an 83.48% drop in related costs. These findings indicate that simulation-driven digital verification offers an effective and scalable way to improve warehouse dispatch accuracy.

Keywords

Warehouse dispatch, simulation modeling, DMAIC, barcode verification, logistics.