Case Study: Big Lots achieves automated, end-to-end forecasting and replenishment with RELEX Solutions

Improved Forecasting and Replenishment through Automation and Adaptability

Big Lots, a U.S. discount retailer with 1,400+ stores and a replenished assortment that grew to 6,000+ SKUs from 500+ vendors, had outgrown time‑consuming manual forecasting and replenishment run through spreadsheets and an outdated system. They needed to automate demand forecasting at store and SKU level, integrate disconnected inbound and outbound planning, and gain the flexibility to adapt to changing lead times and business needs.

Big Lots implemented RELEX over 12 months to unify forecasting and replenishment in a single, configurable system. RELEX automated day‑SKU‑store forecasts (including promotions, seasonality, and lost‑sales adjustments), generated order proposals accounting for lead times and load building, automated complex processes like seasonal chocolate routing, and enabled quick COVID‑era allocation changes and data tagging. The result was end‑to‑end planning, improved transparency and efficiency, better inventory accuracy and responsiveness, and the ability to scale without expanding the team.

Big Lots

Johan Hoover

VP of Allocation & Replenishment