Free fulfillment labor & capacity tool
Warehouse Pick-Pack Cost Calculator
Turn orders, picks, seconds per task, wages, packaging and rework into true cost per order — then test whether the current pick and pack teams can actually handle the volume without overtime or backlog.
Simple fulfillment model
Bottleneck GateBuild the true pick-pack cost per order
Order workload
Pick labor
Pack labor
Shift & support labor
Packaging & consumables
Quality & rework
Overtime & capacity policy
Capacity logicCost uses the labor hours actually required by the entered work content. Capacity uses scheduled headcount × paid shift hours × productive utilization. If required hours exceed regular capacity, the excess is priced at the entered overtime multiplier and the bottleneck stage is flagged.
Cost Stack
Where every fulfillment dollar goes
Capacity Ledger
Required hours versus regular labor capacity
| Stage | Work volume / day | Work content | Required hours | Regular capacity hours | Load | Overtime hours | Capacity signal |
|---|
Volume × Pick Speed
Cost per order sensitivity
Advanced order-profile model
Labor Capacity BoardModel six different fulfillment workflows
Shared warehouse assumptions
Support, quality & policy
Six order profiles
Advanced logicEvery profile contributes its own picks, pick seconds, pack seconds, packaging and rework. Shared picker/packer pools are then stress-tested against the blended workload, so a high-cost profile can be visible even when it is a small share of total volume.
Order Profile Cost Board
Which order types are consuming the most fulfillment resources?
| Rank | Profile | Orders/day | Picks/order | Pick labor/order | Pack labor/order | Packaging/order | Rework/order | Direct profile cost/order | Annual profile cost | Signal |
|---|
Labor Capacity Board
Pick and pack capacity under current and peak volume
Peak Volume Stress Test
Staffing and overtime as order volume rises
| Volume scenario | Orders/day | Pick load | Pack load | Overtime hours/day | Cost/order | Additional pickers needed | Additional packers needed |
|---|
Pick Speed × Pack Speed
Weighted cost/order sensitivity
Scope
Use observed warehouse time standards when available
This calculator is a planning model. Actual pick-pack productivity varies with travel distance, slotting, batch/wave logic, SKU size, cart or AMR support, congestion, replenishment, packaging complexity, ergonomics, training, WMS workflows, carrier cutoffs and quality controls. Use time-study or engineered-labor-standard data when available.