Packaging & Logistics worked example

Bin Location Capacity at 110% bin locations usable: a worked example

What does the result look like when bin locations usable reaches 110%? The full calculation is worked below with real intermediate numbers. Use it to plan small parts and forward pick slotting and confirm SKUs will fit before you assign bin locations.

The inputs for this scenario

  • Units stored per bin location: 120 units / bin (unchanged)
  • Number of bin locations in zone: 48 bins (unchanged)
  • Bin locations usable (not blocked/damaged): 110 % (raised for this scenario; the documented default is 100)
  • Average fill rate per bin: 85 % (unchanged)

Working through the calculation

  • Applying the documented formula (Gross bin capacity = units per bin × bin locations) to the inputs above produces each figure below.
  • At this operating point the engine returns 5,386 units for usable bin capacity, the number this scenario is built around.
  • At this operating point the engine returns 5,760 units for gross bin capacity.
  • At this operating point the engine returns -576 units for unusable bin loss.
  • At this operating point the engine returns 950 units for fill rate loss.

How this compares with the baseline

  • Against the tool's baseline example, where bin locations usable sits at 100% and the headline result is 4,896 units, this scenario comes in 10% above the baseline at 5,386 units.
  • A figure at this level is achievable when bin locations usable is genuinely sustained, not just peaked for a shift. It assumes a uniform units-per-bin and fill rate across every location, so mixed bin sizes or a few oversized SKUs will make the single-number estimate optimistic.

Results at a glance

  • Usable bin capacity: 5,386 units (headline result)
  • Gross bin capacity: 5,760 units
  • Unusable bin loss: -576 units
  • Fill rate loss: 950 units

Run it with your numbers

  • Every input above is editable in the live Bin Location Capacity calculator, which recalculates instantly and can be shared with the inputs intact.

Last reviewed 2026-05-12.