Packaging & Logistics worked example

Order Fulfillment Capacity at 65% labor utilization rate: a worked example

This worked example runs the order fulfillment capacity numbers for a tougher week than the baseline: 65% labor utilization rate instead of the typical 90%. Estimate net order fulfillment capacity from orders per labor hour and labor hours, after utilization and error losses.

The inputs for this scenario

  • Orders processed per labor hour: 18 orders / hr (held at the documented default)
  • Labor hours available on shift: 64 hr (held at the documented default)
  • Labor utilization rate: 65 % (the input this scenario stresses; the baseline uses 90)
  • Order accuracy rate: 99 % (held at the documented default)

Working through the calculation

  • The calculation starts from the formula this tool documents: Gross order capacity = orders per labor hour × labor hours available.
  • Net order capacity works out to 741 orders at these inputs, and this is the headline figure for the scenario.
  • Gross order capacity works out to 1,152 orders at these inputs.
  • Utilization loss works out to 403 orders at these inputs.
  • Rework and error loss works out to 7.49 orders at these inputs.

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 27.78% below the baseline at 741 orders.
  • Use it for daily or weekly volume commitments, staffing decisions, and stress-testing whether a promo spike fits current labor. 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

  • Net order capacity: 741 orders (headline result)
  • Gross order capacity: 1,152 orders
  • Utilization loss: 403 orders
  • Rework and error loss: 7.49 orders

Run it with your numbers

  • To rerun this with your own numbers, open the live Order Fulfillment Capacity calculator, set labor utilization rate to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.