Inventory & Replenishment Analyst

Job Summary

The Warehouse Inventory & Replenishment Analyst will be responsible for maintaining optimal inventory levels within the warehouse by managing the flow of product from bulk/reserve storage to forward pick face locations. This role ensures that pick slots are consistently stocked to meet order demand while minimizing excess in pick faces and preventing out-of-stocks.

Additionally, the analyst will perform core inventory analyst functions including cycle counting, inventory accuracy analysis, shrinkage investigation, safety stock management, and performance reporting. The analyst will monitor real-time inventory data, analyze velocity patterns, and coordinate with warehouse operations to execute timely, efficient replenishment moves.

Essential Duties and Responsibilities

• Replenishment Planning: Monitor pick face inventory levels against minimum thresholds (min/max or dynamic par levels). Generate and prioritize replenishment tasks to transfer products from bulk/reserve storage to active pick locations based on demand velocity, order volume, and slot capacity.
• Inventory Analysis: Monitor key inventory KPIs including stock-out rates, days of inventory outstanding (DIO), inventory turnover, and slow-moving/obsolete (SLOB) stock. Conduct ABC/XYZ analysis to classify inventory and apply appropriate replenishment strategies.
• Inventory Slotting & Optimization: Analyze SKU velocity (fast, medium, slow movers) and physical characteristics to recommend optimal pick face sizing, slot locations, and bulk-to-pick face ratios. Adjust slot configurations as demand patterns change.
• Cycle Counting & Accuracy: Perform regular cycle counts of both bulk and pick face locations to maintain inventory accuracy. Investigate and resolve discrepancies between system stock and physical counts, such as over-picks, shorts, or mis-slots.
• Data Analysis & Reporting: Track key performance indicators (KPIs) including pick face fill rate, replenishment lead time, stock-out events at pick face level, and number of replenishment touches per SKU. Generate daily/weekly reports on replenishment activity and slot utilization.
• Documentation: Maintain comprehensive documentation of reverse logistics processes, procedures, and performance metrics.
• System Management: Maintain WMS SKU Master Data parameters including pick face maximums, reorder points, replenishment triggers, and wave logic. Use WMS or Excel tools to forecast replenishment demand.
• Coordination with Warehouse Teams: Communicate with pickers, put-away associates, and forklift operators to prioritize urgent replenishment tasks. Work with the receiving team to ensure bulk inventory is properly located and available for replenishment.
• Continuous Improvement: Proactively identify opportunities to reduce replenishment frequency (e.g., increasing pick face capacities for A-items), eliminate unnecessary touches, and optimize travel paths between bulk and pick face zones.
• Wave & Order Support: Align replenishment execution with daily order cut-off times and picking waves. Ensure high-velocity SKUs are replenished before peak picking periods to avoid picker downtime.
• Cross-functional Coordination: Work closely with Receiving to resolve Purchase Order/Goods Receipt discrepancies and with Replenishment/Outbound to address stock availability impacts.
• Inventory KPI Reporting: Generate daily, weekly, and monthly reports on key inventory metrics including:
• Root Cause Analysis & Continuous Improvement: Proactively investigate recurring inventory issues (e.g., repeated cycle count failures, phantom inventory). Propose and implement process improvements, such as bin-location audits, put-away accuracy checks, or system configuration changes.
• Carry out additional responsibilities and special projects as directed by management in support of warehouse and logistics operations.

Qualifications

• Bachelor's degree in Supply Chain Management, Operations Management, Logistics, Industrial Engineering, or a related field; equivalent work experience may be considered.
• Proven experience (1–3 years) in warehouse operations, inventory control, replenishment, or related functions within a distribution center or fulfillment environment.
• Working knowledge of Warehouse Management Systems (WMS), LSBC, and other ERP platforms. Familiarity with concepts such as pick-face management, bulk storage locations, replenishment triggers, wave management, and inventory control is preferred. Experience with systems such as Dynamics 365 Business Central, NetSuite, Infor, or similar platforms is an advantage.
• Strong communication, interpersonal, and teamwork skills, with the ability to collaborate effectively across departments and coordinate warehouse activities in a fast-paced environment.
• Detail-oriented with a strong focus on accuracy, organization, and operational excellence.
• Proficient in Microsoft Office applications, particularly Microsoft Excel (PivotTables, VLOOKUP, XLOOKUP, sorting, and filtering), with the ability to analyze inventory, pick-data, and velocity reports to support replenishment and slotting strategies.
• Strong analytical and problem-solving skills, with the ability to interpret operational data and make data-driven decisions to improve warehouse efficiency.