LeanForger

Working in warehousing gives you a front-row seat to both efficiency and inefficiency. When I became a warehouse supervisor, I saw a massive amount of wasted labor. Over time, we introduced one-piece-flow systems and lean methods to eliminate that waste—and within a year, we doubled productivity. We handled higher volume and expanded into new value streams without adding staff. I wanted to help other teams achieve the same results, not just in warehousing. That idea became LeanForger—a tool anyone can use to accurately plan staffing and workload needs. What started as a simple labor calculator evolved into a multicycle process simulator, and later into an automatic daily labor planner that reallocates teams across value streams as demand changes. Together, these tools replace guesswork with math and visibility. While I used AI to assist with development, the underlying logic, arithmetic, and problem-solving are entirely my own—and it still took about 9 months to build to my standard. LeanForger is far from finished, and I’d love your feedback. What works? What doesn’t? And if you know people who should see this, I’d appreciate the help getting it in front of them. Thanks to the Product Hunt community for the support.