Pharmaceutical Packaging & Serialization worked example

Aggregation Labor at 12% setup, handling, and delay allowance: a worked example

What does the result look like when setup, handling, and delay allowance reaches 12%? The full calculation is worked below with real intermediate numbers. Use it when aggregation labor in pharmaceutical packaging and serialization is changing rate or allowance and you want to see the impact.

The inputs for this scenario

  • Cases to aggregate: 120 units (unchanged)
  • Aggregation scan-and-pack rate: 12 units / min (unchanged)
  • Setup, handling, and delay allowance: 12 % (raised for this scenario; the documented default is 10)

Working through the calculation

  • Applying the documented formula (Base aggregation labor time = aggregation labor workload รท aggregation labor completion rate) to the inputs above produces each figure below.
  • At this operating point the engine returns 11.2 hr for required aggregation labor time, the number this scenario is built around.
  • At this operating point the engine returns 10 hr for base aggregation labor time.
  • At this operating point the engine returns 12 % for aggregation labor allowance applied.
  • At this operating point the engine returns 12 pieces / min for aggregation labor completion rate.

How this compares with the baseline

  • Against the tool's baseline example, where setup, handling, and delay allowance sits at 10% and the headline result is 11 hr, this scenario comes in 1.82% above the baseline at 11.2 hr.
  • A figure at this level is achievable when setup, handling, and delay allowance is genuinely sustained, not just peaked for a shift. It assumes a constant scan rate and does not separately model the time lost to failed reads, reprints, or re-aggregation of rejected cases.

Results at a glance

  • Required aggregation labor time: 11.2 hr (headline result)
  • Base aggregation labor time: 10 hr
  • Aggregation labor allowance applied: 12 %
  • Aggregation labor completion rate: 12 pieces / min

Run it with your numbers

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

Last reviewed 2026-05-12.