Enhancement of In-Store Product Replenishment Flow and Introduction of Pull Approach in a Food Retail Chain

Elisa Vieira, Larissa Tomaz, José Leitão, João Fernandes and José Dinis-Carvalho ()
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Elisa Vieira: Centro Algoritmi, University of Minho, 4800-058 Guimarães, Portugal
Larissa Tomaz: Centro Algoritmi, University of Minho, 4800-058 Guimarães, Portugal
José Leitão: Centro Algoritmi, University of Minho, 4800-058 Guimarães, Portugal
João Fernandes: Centro Algoritmi, University of Minho, 4800-058 Guimarães, Portugal
José Dinis-Carvalho: Centro Algoritmi, University of Minho, 4800-058 Guimarães, Portugal

Logistics, 2025, vol. 9, issue 2, 1-16

Abstract: Background : Due to the highly competitive nature of the retail sector, companies need to improve their operational efficiency. This study focuses on the application of the concepts of Lean production in the process of replenishing products on the shelves of the shops of one of the largest food retail chains in Portugal. Methods : This study aims to apply a transition from a “push” to a “pull” approach, based on real-time consumption. During a 5-day test, the impacts of implementing Lean principles and ergonomic trolleys in the process were investigated. Results : The test led to improved efficiency in product replenishment by eliminating pallets and reducing unfavourable product handling from the initial process. The implementation of a replenishment system in this manner allowed a reduced labour requirements from 28.4 to 19.2 man-hours per day and, the elimination of unnecessary handling and increase of product availability were reflected in gains on operational time and in replenishment time. Conclusions : This study provides empirical evidence for the effectiveness of Lean pull systems in retail replenishment, demonstrating a 32% reduction in labour hours.

Keywords: lean philosophy; pull replenishment; flow principle; food retail efficiency (search for similar items in EconPapers)
JEL-codes: L8 L80 L81 L86 L87 L9 L90 L91 L92 L93 L98 L99 M1 M10 M11 M16 M19 R4 R40 R41 R49 (search for similar items in EconPapers)
Date: 2025
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