Lean Manufacturing & Operations worked example

Supermarket Replenishment Quantity with downstream consumption rate of 50 units/hr: a worked example

This scenario runs the supermarket replenishment quantity calculation on the strong side: downstream consumption rate of 50 units/hr, with every other input held at its documented default. Use this calculator when sizing supermarket lanes or shelves in a pull system to ensure enough stock to cover the replenishment cycle without excess.

The inputs for this scenario

  • Downstream consumption rate: 50 units/hr (raised for this scenario; the documented default is 20)
  • Replenishment loop cycle time: 4 hrs (unchanged)
  • Safety stock multiplier: 1.3 x (unchanged)

Working through the calculation

  • Applying the documented formula (Replenishment Qty = Consumption Rate x Cycle Time x Safety Multiplier) to the inputs above produces each figure below.
  • At this operating point the engine returns 260 units for replenishment quantity (units), the number this scenario is built around.
  • At this operating point the engine returns 260 value for base product.
  • At this operating point the engine returns 1 x for multiplier.
  • At this operating point the engine returns 200 value for factor a x b.

How this compares with the baseline

  • Against the tool's baseline example, where downstream consumption rate sits at 20 units/hr and the headline result is 104 units, this scenario comes in 150% above the baseline at 260 units.
  • Use it when designing or right-sizing a kanban supermarket between two processes running at different rhythms. Treat this as a target state: the delta against the baseline quantifies what the improvement is worth before you commit to chasing it.

Results at a glance

  • Replenishment quantity (units): 260 units (headline result)
  • Base product: 260 value
  • Multiplier: 1 x
  • Factor A x B: 200 value

Run it with your numbers

  • Every input above is editable in the live Supermarket Replenishment Quantity calculator, which recalculates instantly and can be shared with the inputs intact.

Last reviewed 2026-05-12.