Warehouse Pick Route Estimator

Inputs

Orders Avg lines per order Avg units per line Pick route distance (m) No of simultaneous orders picked Overlap level i None/Low/Medium/High controls how often lines overlap across simultaneous orders. Travel speed i Walking slow: 0.9 m/s
Walking avg: 1.2 m/s
PPT (powered pick truck): 1.8 m/s Time per pick line (sec) Time per unit (sec) Fixed allowance per run (sec) i Covers setup, handling, checks, and other per-route overhead not captured by line or unit time. Number of shifts Hours per shift

Results

Total routes

0.00

Total distance (m)

0.00

Total lines picked

0.00

Total unique lines picked

0.00

Total units picked

0.00

Average distance per route (m)

0.00

Average distance per order (m)

0.00

Total time for all orders (h:m)

0h 0m

Congestion time (h:m)

0h 0m

FTE shifts required

0.0

Orders per hour

0.00

Units per hour

0.00

Lines per hour

0.00

Average run time (min)

0.00

Time Bucket Chart

Travel0h 0m

Line handling0h 0m

Unit handling0h 0m

Fixed allowance0h 0m

Congestion0h 0m

Assumptions & Formulas

This is a rough planning model with simple per-route productivity assumptions:

Total routes = ceil(orders / simultaneous orders)
Overlap level (none/low/medium/high) drives a Pareto-style curve with lines/order
Line handling time includes a built-in medium identification penalty as simultaneous orders increase
Total distance = total routes × pick route distance
Average distance per order = total distance / orders
Lines per route = simultaneous orders × avg lines per order
Units per route = lines per route × avg units per line
Average run time = (route travel + line work + unit work + fixed allowance)
Hourly outputs use a built-in productivity factor of 85%
Congestion uses a capped multiplier based on active pickers and route compression (shorter routes increase congestion pressure)
Orders, units, and lines per hour are derived from run rate and per-route content

Note: this is a rough planning model; real rates vary due to layout, congestion, product mix, and process differences.