How Lean Inc. and TrainSocially Standardized Safety Training for a Global Retailer’s Distribution Network.
1. The Executive Summary
Daiso, a premier global “value store” retailer, faced the challenge of maintaining rigorous safety and operational standards across its rapidly expanding North American distribution centers. By partnering with Lean Inc., Daiso transitioned from manual, fragmented training methods to a centralized, AI-powered digital ecosystem.
2. The Challenge: “The Growth Gap”
As Daiso scaled, they encountered three primary “profit leaks” in their warehouse operations:
- Inconsistent Onboarding: New hires at different locations received varied levels of safety instruction.
- Compliance Tracking: Manual paper logs for operations training and OSHA forklift certification were difficult to audit and prone to error.
- Operational Waste: Lack of standardized Lean 5S practices led to slower order fulfillment and increased safety incidents.
3. The Solution: The Lean Inc. and Train Socially Ecosystem
The Lean Inc. team implemented a two-pronged strategy:
A. Digital Infrastructure via TrainSocially We deployed a custom-branded Daiso Training Portal that serves as the “Single Source of Truth” for all employees.
- Automated Certification: Digital OSHA forklift and pallet jack training with automated renewal reminders.
- Scalable Curriculum: High-definition video modules that can be accessed via mobile or warehouse kiosks.
B. Physical Lean Integration To support the digital training, customers utilize Lean Warehouse Products to “visualize” safety on the floor:
- Mighty Line Floor Tape: To clearly define pedestrian walkways and equipment zones.
- Rack Armour Protection: To minimize facility damage from high-frequency forklift traffic.
- RackSack Trash Solution: To optimize space and trash segregation.
4. The Results: Measurable Impact
- 100% Compliance: Achieved a “Zero-Gap” audit trail for all powered industrial truck (PIT) operators.
- Reduced Onboarding Time: Cut training-to-floor time by 95% through on-demand digital modules.
- Culture Shift: Standardized the “Daiso Way” of warehouse organization, significantly reducing “search waste” and equipment collisions.
“By moving our training to the TrainSocially platform, we didn’t just check a compliance box—we built a scalable culture of safety that grows with us.”