Background: Replenishment process is one of the success factors for a more efficient management of operations and a regained profitability. The application of the principles of lean manufacturing in the field of industrial logistics, where substantial improvements in the replenishment process are necessary, is relevant with the objective of optimising the replenishment flow of raw materials from assembly lines in order to propose and implement robust solutions capable of mitigating or even eliminating all types of waste and maximising the productivity of value-added activities. Methods: To achieve this goal, the paper follows the spirit of the DMAIC (Define, Measure, Analyse, Improve and Control) and 5-Why methods that allow the mapping of internal processes of factory logistics in the particular case of a Wire Harness Automotive Plant. Results: Based on the data collected, as well as on specific analysis methods, simulations are launched to challenge and validate the improvements made to the replenishment process. Conclusions: Several generalisable lessons are learnt regarding replenishment flow management, covering topics such as inventory traceability, in addition to logistics costs and process flow optimisation.

The world population continues to grow, generating a rapid consumption of the earth’s resources that do not have enough time to regenerate. On one side, some economists warn about restricting the population increase that penalizes countries favoring birth control. Conversely, the widespread way of thinking pushing toward galloping demography can be uneconomic. Is the straight correlation between solid demographics and high economic growth correct in a complex and highly nonlinear system? Is the assumption behind the quasi-postulate indicating infinite growth true? This paper attempts to explain the divergent viewpoints regarding the impact of population size on economic development by offering a holistic model instead of a linear cause-and-effect analysis and its variations we find in the majority of works on the subject that neglect the higher-order interactions between various factors, generating approximate, even biased answers due to a legitimate desire to simplify complex phenomena. A systemic model integrating population growth, technology, and economy in a fully endogenous way and in a finite world is proposed, simultaneously highlighting sustainability's role through two main variables, namely “Population” and “Carrying Capacity” of earth. The model tries to find the right balance between those, alarmists, who advocate a soon uncontrolled situation, and others, easygoing, and warn against any drastic form of growth limitation susceptible to plunging billions of people into poverty. It contributes to establishing the conditions for preserving the environment while stimulating the economy in a sustainable manner, with population evolution in the foreground.