Merchandise Replenishment Methods and Times

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We are looking for a consultant with experience in methods and time studies to analyze the merchandise replenishment operation in large-format stores.

The project aims to determine, through on-site observation and timing, the standard replenishment times, subsequently allowing for the sizing of labor needs and the improvement of store operational planning.

• Analyze the complete replenishment cycle, from the collection/movement of merchandise to the completion of replenishment and the handling of respective waste and surpluses.
• In particular, we would like to obtain differentiated times according to variables such as:

· Pallet typology: homogeneous, mixed, half-pallet, 1/4 pallet, display, or other relevant typologies;

· Product family;

· Number of boxes per pallet;

· Number of SKUs/references per pallet;

· Quantity of units;

· Number of aisles/locations involved;

· Distance traveled between the stock area and the sales location;

· Typology of equipment used in movement;

· Existence of surplus stock after replenishment;

· Replenishment execution conditions, namely whether the store is open or closed to the public.

• We intend for the analysis to allow the total time to be decomposed, whenever possible, into different work elements, namely:

· preparation and collection of merchandise;

· movement to the sales area;

· opening/depalletizing;

· travel between locations;

· opening of boxes;

· placing the product on the shelf;

· handling of cardboard and plastic;

· management of surpluses;

· return to the stock area;

· handling of the empty pallet.

1. Methodology used for the methods and time study;
2. Sampling plan and recommended number of observations;
3. Timing of operations on the ground;
4. Database with all observations performed;
5. Statistical analysis of the times obtained;
6. Average times, median, and relevant percentiles;
7. Standard times per pallet typology/operation;
8. Productivity indicators, namely boxes/hour, pallets/hour and, when applicable, units/hour;
9. Identification of the main factors explaining the variation in replenishment time;
10. Model that allows for estimating labor hour needs based on the volume and typology of merchandise to be replenished;
11. Identification of opportunities to improve the work method.

Location: Lisbon Region
Scope: Consulting project with fieldwork in three large-format stores.

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