Lean Thinking in Action: Yellow Belt Training for FLYJAC Logistics, Chennai
Conducted by Dr. Gopal Sivakumar, Ph.D
Professor – Operational Excellence & CEO, Vision Excellence Consulting
FLYJAC Logistics Pvt. Ltd., a leading name in integrated logistics and supply chain solutions, took a decisive step
toward operational excellence by organizing a focused
Lean Yellow Belt Training program
for its team in Chennai.
The session was led by Dr. Gopal Sivakumar,
a well-known Lean and Six Sigma expert with decades of experience in industry transformation.
With logistics becoming increasingly competitive and customer expectations rising, organizations like FLYJAC are
embracing structured problem-solving methods to eliminate delays, reduce defects and build seamless workflows.
This Yellow Belt program acted as a strong foundation to equip their team members with the mindset and tools needed
to drive continuous improvement from the ground up.
Building a Culture of Continuous Improvement
The training highlighted the essentials of Lean principles, focusing on identifying waste, improving process flow
and enhancing customer value. Participants were introduced to practical, real-world problem-solving approaches that
can be applied immediately in logistics operations such as warehousing, transportation, inventory handling and
order processing.
Dr. Gopal emphasized how Lean is not just a set of tools, but a structured way of thinking that encourages teams to
continuously observe, analyze and refine processes. His examples from manufacturing, logistics and service
industries helped the FLYJAC team understand the power of small, consistent improvements.
Key Highlights of the Training
- Introduction to Lean Thinking and the importance of customer value.
- Understanding the 8 types of waste in logistics operations.
- Basics of DMAIC – Define, Measure, Analyze, Improve, Control.
- Hands-on problem solving using Lean tools and templates.
- Value Stream Thinking and identifying bottlenecks in processes.
- Team-based learning with examples relevant to supply chain and logistics.
Engaged Participation from FLYJAC Team
The participants showed strong enthusiasm throughout the program. Discussions revolved around real challenges
such as shipment delays, rework, mis-routing, unnecessary movements and documentation errors.
Through interactive exercises, teams learned how to look at these issues through a Lean lens and identify
opportunities for improvement.
Dr. Gopal encouraged every participant to take ownership of at least one improvement initiative in their
department. The goal is to create measurable impact over the next few weeks as Yellow Belt learners begin applying
their new knowledge in live operations.
Lean Tools that Make a Difference
The FLYJAC team explored practical tools including:
- Process Mapping
- SIPOC
- Fishbone Diagram
- 5 Why Analysis
- Pareto Chart Thinking
- Waste Identification Templates
These tools will help them diagnose root causes faster and implement structured improvements that enhance
efficiency and reduce operational cost.
A Step Towards Lean-Driven Excellence
The Lean Yellow Belt program conducted for FLYJAC Logistics marks an important milestone in strengthening
continuous improvement culture within the organization.
With expert guidance from Dr. Gopal Sivakumar,
the team is now equipped with clear direction, practical tools and a shared vision for operational excellence.
FLYJAC’s commitment to upskilling its workforce showcases its dedication to delivering faster, error-free and
customer-centric logistics solutions in today’s fast-paced supply chain landscape.
