In Lean, the most common waste is walking, waiting, searching and repeated lifting. A trolley designed around the process cuts this waste directly — and supports 5S by keeping the workplace organised.
Trolleys That Support Lean
- Kitting carts: slots for a complete set of parts for one cycle, so operators don't walk to several locations
- Task-specific carts: places for tools or parts in the order they are used
- Carts at workstation height: slide work across without lifting
- Tugger carts: deliver parts in timed rounds — see tugger carts
How They Support 5S
- Sort / Set in order: every item has its own place on the cart, so anything missing is obvious
- Shine: drip trays and easy-to-clean surfaces
- Standardise: colour-code or label carts by line or task, and mark parking spots on the floor
Start by observing real work: watch what operators walk to fetch, what they lift often and where they put things, then design the cart so items are close at hand in the order they are used. The best trolley is the one designed from the actual process.
Design Inputs
- The list of parts or tools and the order they are used
- Bench or workstation height
- The route and parking points
Summary
Custom trolleys designed around the process cut walking, searching and lifting — a low-cost tool that delivers clear results for Lean and 5S.