Question 1

How is warehouse space utilisation calculated?

Accepted Answer

Space utilisation = occupied storage positions / total storage positions x 100%. Theoretical maximum is 100% but practical maximum is 85-90% to allow access and picking flexibility. Below 70% suggests the facility is oversized; above 95% creates operational problems.

Question 2

What is pick productivity in warehousing?

Accepted Answer

Pick productivity = lines picked / hours worked. A manual pick operation averages 80-120 lines per hour. Voice picking and RF scanning can achieve 150-200 lines per hour. Goods-to-person automation can exceed 500 lines per hour. Our calculator factors in travel, pick, and put-down time.

Question 3

How do I calculate storage cost per unit?

Accepted Answer

Storage cost per unit = (annual warehouse cost / average inventory units on hand). Annual warehouse cost includes rent, rates, utilities, labour, equipment, and insurance. If total cost is $500,000 and average units are 50,000, cost is $10 per unit per year or $0.83 per unit per month.

Question 4

Are these warehousing tools free?

Accepted Answer

Yes - completely free, no sign-up required. Results export to CSV or PDF.

Free Warehousing Tools & Calculators

Warehousing calculators for DC managers

Warehousing Tools - FAQ