WarehouseOps editorial · Updated 20 September 2026
Measure work consistently
Separate receiving, put-away, picking, packing and dispatch. Record productive hours and completed units using the same scope. Avoid mixing lines per paid hour with lines per productive hour.
Worked example
1,920 pick lines at 40 lines per productive hour require 48 productive hours. An eight-hour shift at 75% productive time gives six hours per person. Eight people must attend; with 10% absence, the roster requirement is 8 ÷ 0.9, rounded up to nine. Other work adds to this requirement.
Separate base from peak
The tool shows average and peak demand, then lets you choose what share of extra peak capacity to retain. The balance may require planned flexible capacity, scheduling or process changes; it does not disappear.
Check costs and constraints
Set actual operating days for cost-per-unit calculations. Validate breaks, skill coverage, supervision, equipment and applicable working-hour rules with the responsible team.