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

Author

Listed:
  • 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)

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.

Suggested Citation

  • Elisa Vieira & Larissa Tomaz & José Leitão & João Fernandes & José Dinis-Carvalho, 2025. "Enhancement of In-Store Product Replenishment Flow and Introduction of Pull Approach in a Food Retail Chain," Logistics, MDPI, vol. 9(2), pages 1-16, May.
    • Handle: RePEc:gam:jlogis:v:9:y:2025:i:2:p:61-:d:1657362
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    References listed on IDEAS

    as
    1. Diana Filipe & Carina Pimentel, 2023. "Production and Internal Logistics Flow Improvements through the Application of Total Flow Management," Logistics, MDPI, vol. 7(2), pages 1-22, June.
    2. Yanfang Qin & Hongrui Liu, 2022. "Application of Value Stream Mapping in E-Commerce: A Case Study on an Amazon Retailer," Sustainability, MDPI, vol. 14(2), pages 1-16, January.
    3. Pedro Alexandre Marques & Diana Jorge & João Reis, 2022. "Using Lean to Improve Operational Performance in a Retail Store and E-Commerce Service: A Portuguese Case Study," Sustainability, MDPI, vol. 14(10), pages 1-19, May.
    4. Radojko LUKIC, 2012. "The Effects of Application of Lean Concept in Retail," Economia. Seria Management, Faculty of Management, Academy of Economic Studies, Bucharest, Romania, vol. 15(1), pages 88-98, June.
    5. Cox, Andrew & Chicksand, Dan, 2005. "The Limits of Lean Management Thinking:: Multiple Retailers and Food and Farming Supply Chains," European Management Journal, Elsevier, vol. 23(6), pages 648-662, December.
    6. Helena Macedo & Larissa Tomaz & Levi Guimarães & Luís Cerqueira-Pinto & José Carlos Sá & José Dinis-Carvalho, 2025. "Development of a Classification Model for Value-Added and Non-Value-Added Operations in Retail Logistics: Insights from a Supermarket Case Study," Sustainability, MDPI, vol. 17(7), pages 1-15, April.
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