Prolonged cargo offloading cycle times represent a significant challenge within logistics operations, contributing to yard congestion, longer truck turnaround times, and increased operational costs. Reducing non-value-adding time and activities is crucial for maintaining operational efficiency and ensuring sustainable service delivery. Lean manufacturing offers a structured philosophy for elimination of waste, while the DMAIC (Define–Measure–Analyze–Improve–Control) methodology provides an organized, data driven approach for improving processes. The aim of this research is to illustrate how an application of an integrated lean approach DMAIC methodology could assist in reducing cargo offloading cycle times within the logistics operations. This research employs a case study-based research design focused on truck offloading activities. Quantitative data was collected using time studies and observations during peak and normal operating hours. Lean manufacturing techniques including Value Stream Mapping (VSM), fishbone diagram, and 5-Why analysis are applied within the DMAIC framework to explore the root causes of longer cycle times. The results illustrate that the root causes of prolonged offloading cycle times are lack of process standardization. Improvement opportunities focused on elimination of waste, standardized work procedures, and optimized process flow in alignment with DMAIC methodology. The integration of Lean approach with DMAIC methodology offers a systematic approach for reducing offloading cycle times.

Keywords

Lean Manufacturing, DMAIC, Cargo Offloading, Cycle Time Reduction, Logistics Operations