Enhancement of in-store product replenishment flow and introduction of pull approach in a food retail chain

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.