How many order lines can one picker realistically do in an hour, and does your team get through the day's work? Fill in how long a pick takes, how much of the shift is actually picking, and how many lines you ship, and you see whether you finish on time or run into overtime.
Not orders: lines. One order with five different products counts as five. Take a normal week from your order system and divide by working days.
How many people are actually picking during the shift. Do not count team leads, packers or receiving staff unless they pick too.
Paid hours per picker per shift. Breaks stay in here, they come off in the next field.
Time from arriving at the location to the item being in the box or on the trolley. Time ten picks with a phone and take the middle one. Bulk picking is often 20 to 30 seconds, small parts picking 45 to 90.
Breaks, walking between zones, waiting, searching for stock, paperwork and fixing mistakes. Twenty per cent is normal; thirty is common in warehouses where stock is often not where the list says.
64.0
Picks per hour, per person
The rate you can plan with, not the rate on paper.
Everyone picking for the whole shift at that rate.
Above 100% means the work does not fit in the shift.
Total hours of picking the day's lines actually take.
What spills into overtime or tomorrow morning.
A one-page summary with your figures, the method and what the answer means.
Most of the lost time goes into routes and hunting for stock. Both are decided by how work is sent to the floor.
See how directed picking changes the rateIn plain terms: an hour has 3,600 seconds, but nobody picks for all of them. Take out breaks, walking to the start of a round, waiting for a truck, printing, questions and rework, and what is left is real picking time. Divide that by the seconds one pick takes and you have the rate. Multiply by people and hours and you know what the team can do in a day.
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In most warehouses a picker spends more time moving than picking. Shortening routes, grouping orders into one round and putting fast movers near the front does more for your rate than pushing people to move faster.
If stock is regularly not where the list says, every wrong location costs a minute or two and nobody records it. That is why measured rates come out well below the rate people believe they achieve.
It depends entirely on what you pick. Full pallets can be 20 to 40 moves an hour, case picking often 60 to 120 lines, small parts picking 40 to 80. Compare yourself with your own last quarter, not with someone else's warehouse.
Usually because the time lost figure is higher than assumed. Raise it until the calculator matches the lines you actually ship; that gap is your improvement potential in one number.
Loading metres, floor area, volume and trailers needed, from your own pallet sizes and stacking height.
Volumetric weight calculatorDimensional weight, real weight and the chargeable weight your carrier actually bills.
Warehouse space calculatorSquare metres for a given number of pallet positions, including aisles and support space.
Loading metres, stock levels and order points are only as good as the stock data behind them. That is what a warehouse management system keeps accurate, every movement, without anyone maintaining a spreadsheet.