Shelf Replenishment

Store shelf replenishment from stock check to product on shelf

Retail
Sign Up to Use

Lead 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%