Improvement in picking operations in retail product warehouse using slotting, multiproduct ABC segmentation and lean warehousing

This study proposes an improvement in picking operations in a retail warehouse through the implementation of the multi-product ABC methodology, storage policies, and lean warehousing validated by the implementation of simulation tools. The initial diagnosis revealed low resource utilization, high order preparation times, and low compliance with the Fill Rate indicator. A simulation model was designed using Arena and Flexsim tools to analyze the current process and evaluate improvement scenarios. The proposed inventory reorganization based on product rotation reduced total preparation time by up to 22%, improved warehouse resource utilization, and increased productivity by 38%. The results demonstrate that the use of slotting and ABC classification techniques significantly contribute to the warehouse's operational efficiency.