How this calculator works
Warehouse managers need to know if available staff can handle daily order volume and what the shift will cost. A simple time-based model helps separate required effort from hours on the payroll.
What the calculation does
Multiply the average order lines by minutes per pick and add packing time. Divide the total required order minutes by the productive minutes available per worker to estimate required staffing. Compare planned worker capacity and paid shift wages.
Important limitations
Uses a common time-per-order assumption, not live warehouse measurements. Travel time, congestion, breaks, returns, batching and shift overlap should be reflected in actual observed rates and productive utilization.
Common questions
What is productive utilization?
The percentage of paid shift minutes available for direct picking and packing once breaks and indirect work are accounted for.
Why is labor cost based on paid time?
Employees are paid for shifts, not only minutes handling orders. The paid-shift estimate is therefore a different number from the theoretical task labor cost.
How do I handle mixed orders?
Use a weighted average number of lines and average packing time from real order samples.