How Retailers Can Improve Stock Movement Behind the Scenes

Retailers can make stock movement more manageable by reviewing where goods are received, stored, picked and replenished. The aim is to avoid unnecessary transfers, keep routes usable and choose handling equipment that suits the cartons, floor surfaces and people involved. Start by following one delivery through the store and recording where it gets moved twice.

A customer sees a tidy shelf or a parcel ready for collection. Behind that result, staff may have carried stock from the delivery point, shifted it to make room for another shipment and retrieved it again to fill an order.

A closer look at those movements can reveal practical improvements without changing the store’s entire layout.

Where is stock being handled more than necessary?

Follow the goods from arrival to their next useful destination. Look for cartons that are put down temporarily, moved aside for access and then collected again. Each transfer should have a clear purpose, such as checking quantities, allocating stock or preparing products for sale.

A delivery left just inside the back door might seem convenient. It becomes less useful if the next delivery cannot enter until someone moves it.

Consider a hypothetical delivery of 24 cartons. If six cartons can be transported safely per trolley load, moving them from receiving to their assigned locations takes four loaded trips. Moving the whole delivery to a temporary holding area first creates another four loaded trips.

That arithmetic does not predict time savings. It shows why the route and destination matter as much as the equipment.

Which movements can be grouped sensibly?

Group stock by its next destination where that fits the store’s workflow. Cartons for the same department can travel together, while stock allocated to online orders can go to the appropriate picking or packing area. This gives staff a reason for each trip and a clear place to unload.

For example, a homewares retailer could separate shelf replenishment from stock reserved for customer orders during the receiving check. Both need to move, but they do not necessarily need to pass through the same holding area.

Batching has limits. A larger load is not an improvement if it becomes unstable, blocks the operator’s view or requires excessive effort to control. Plan manageable loads rather than trying to fit an entire delivery onto one trolley.

What should retailers check before choosing a trolley?

Match the trolley to the stock and the route, rather than choosing by load rating alone. Deck dimensions, wheel selection, manoeuvring space and storage requirements all affect whether the equipment will be useful. Include the staff who regularly move stock in the selection process.

For boxed goods and bulky products, platform and flatbed trolleys provide a deck for transporting loads between receiving, storage and replenishment areas. Compare individual models against the store’s actual requirements.

A wide deck may accommodate larger cartons but be awkward at a tight stockroom corner. A folding handle may help where equipment storage is limited. Side panels may be useful for containing suitable loads, while an open platform offers access for loading from different sides.

Check the complete route, including doorways and floor transitions. Confirm the model’s rated capacity and intended use before purchasing.

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Why does an adequate load rating not settle the decision?

A trolley’s rated capacity describes a limit for the equipment. It does not establish that every load below that figure is practical for a person to move. The floor, gradient, wheels and frequency of use also influence the task.

WorkSafe WA’s trolley guidance identifies loaded weight, floor surface and gradient, and castor design as factors affecting pushing and pulling forces. WorkSafe Victoria also recommends considering the task, user and workplace layout when selecting a trolley.

Include loading and unloading in the review. Equipment that moves cartons across a room does not remove the lifting involved in placing them on the deck or transferring them to shelves. Some tasks may need a different handling aid or a change in storage height.

How can stock movement fit around customers and online orders?

Give replenishment, customer collections and dispatch their own defined places within the workflow. Staff should be able to tell which goods are ready to move and where they belong, without mixing checked stock, unprocessed deliveries and completed orders.

Where practical, schedule bulky replenishment outside the store’s busiest customer periods. Keep stock routes and trolley parking positions clear rather than relying on staff to find spare space each time.

Before changing the setup, check:

• Where deliveries can be received and checked.
• Which cartons share a destination.
• Whether loaded trolleys fit the route and remain manageable.
• How goods are loaded, unloaded and placed on shelves.
• Where equipment is stored and who reports faults.

Trial the arrangement with the people who use it, including during a busy delivery period. Their feedback can identify a tight turn, awkward unloading point or missing storage space before it becomes part of the daily routine.