Packaging & Logistics worked example

Bin Location Capacity at 72% bin locations usable: a worked example

This worked example runs the bin location capacity numbers for a tougher week than the baseline: 72% bin locations usable instead of the typical 100%. Estimate usable bin location capacity from units per bin and bin count, after unusable bins and fill rate losses.

The inputs for this scenario

  • Units stored per bin location: 120 units / bin (held at the documented default)
  • Number of bin locations in zone: 48 bins (held at the documented default)
  • Bin locations usable (not blocked/damaged): 72 % (the input this scenario stresses; the baseline uses 100)
  • Average fill rate per bin: 85 % (held at the documented default)

Working through the calculation

  • The calculation starts from the formula this tool documents: Gross bin capacity = units per bin × bin locations.
  • Usable bin capacity works out to 3,525 units at these inputs, and this is the headline figure for the scenario.
  • Gross bin capacity works out to 5,760 units at these inputs.
  • Unusable bin loss works out to 1,613 units at these inputs.
  • Fill rate loss works out to 622 units at these inputs.

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 28% below the baseline at 3,525 units.
  • Use it during slotting, seasonal ramp planning, or when deciding whether a fast-moving SKU family fits in an existing pick zone. A result at this level usually justifies acting on the stressed input before touching anything else, because every other figure in the table is downstream of it.

Results at a glance

  • Usable bin capacity: 3,525 units (headline result)
  • Gross bin capacity: 5,760 units
  • Unusable bin loss: 1,613 units
  • Fill rate loss: 622 units

Run it with your numbers

  • To rerun this with your own numbers, open the live Bin Location Capacity calculator, set bin locations usable to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.