Shelf Replenishment
Store shelf replenishment from stock check to product on shelf
RetailLead Time
9.4h
Cycle Time
1.9h
Wait Time
7.5h
PCE
16.0%
Stages
7
Bottleneck
Waste/Markdown Processing
Value-Add vs Non-Value-Add
Value-Add (VA)
An activity is value-add if it meets all three criteria:
- The customer is willing to pay for it
- It transforms the product or service
- It is done right the first time
Examples: Assembly, diagnosis, treatment, coding, machining, testing
Non-Value-Add (NVA)
Activities that consume time or resources but don't add value from the customer's perspective:
- Waiting — queues, approvals, batching delays
- Transport — moving materials or information
- Motion — unnecessary movement of people
- Rework — correcting defects or errors
- Over-processing — doing more than required
Note: Some NVA is necessary (compliance, safety). Target unnecessary NVA first.
Process Timeline
Value-Add vs Non-Value-Add
Bottleneck Analysis
Stage Efficiency
| # | Stage | Cycle (h) | Wait (h) | VA | Resource | Defect % | Efficiency |
|---|---|---|---|---|---|---|---|
| 1 | Stock Level Check | 0.25 | 0.0 | VA | System/Staff | 5.0% | 100.0% |
| 2 | Replenishment Order Generated | 0.1 | 1.0 | VA | System | 3.0% | 9.1% |
| 3 | Pick from Backroom | 0.5 | 2.0 | VA | Stock Crew | 6.0% | 20.0% |
| 4 | Transport to Floor | 0.15 | 0.5 | NVA | Stock Crew | 2.0% | 23.1% |
| 5 | Shelf Stocking | 0.5 | 0.0 | VA | Stock Crew | 8.0% | 100.0% |
| 6 | Facing & Merchandising | 0.15 | 0.0 | VA | Stock Crew | 4.0% | 100.0% |
| 7 | Waste/Markdown Processing | 0.25 | 4.0 | NVA | Duty Manager | 10.0% | 5.9% |