Packaging & Logistics worked example

Order Fulfillment Capacity at 99% labor utilization rate: a worked example

This scenario runs the order fulfillment capacity calculation on the strong side: 99% labor utilization rate, with every other input held at its documented default. Use it to plan staffing, check if you can absorb a demand spike, and size labor before peak season.

The inputs for this scenario

  • Orders processed per labor hour: 18 orders / hr (unchanged)
  • Labor hours available on shift: 64 hr (unchanged)
  • Labor utilization rate: 99 % (raised for this scenario; the documented default is 90)
  • Order accuracy rate: 99 % (unchanged)

Working through the calculation

  • Applying the documented formula (Gross order capacity = orders per labor hour × labor hours available) to the inputs above produces each figure below.
  • At this operating point the engine returns 1,129 orders for net order capacity, the number this scenario is built around.
  • At this operating point the engine returns 1,152 orders for gross order capacity.
  • At this operating point the engine returns 11.52 orders for utilization loss.
  • At this operating point the engine returns 11.4 orders for rework and error loss.

How this compares with the baseline

  • Against the tool's baseline example, where labor utilization rate sits at 90% and the headline result is 1,026 orders, this scenario comes in 10% above the baseline at 1,129 orders.
  • Use it for daily or weekly volume commitments, staffing decisions, and stress-testing whether a promo spike fits current labor. Treat this as a target state: the delta against the baseline quantifies what the improvement is worth before you commit to chasing it.

Results at a glance

  • Net order capacity: 1,129 orders (headline result)
  • Gross order capacity: 1,152 orders
  • Utilization loss: 11.52 orders
  • Rework and error loss: 11.4 orders

Run it with your numbers

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

Last reviewed 2026-05-12.