WMS, Warehouse Labor & Fulfillment worked example

Replenishment Workload 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 replenishment workload in wms, warehouse labor and fulfillment needs a defensible run time before a quote goes out.

The inputs for this scenario

  • Cases to replenish this shift: 120 units (unchanged)
  • Replenishment rate per operator: 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 replenishment workload time = replenishment workload workload รท replenishment workload completion rate) to the inputs above produces each figure below.
  • At this operating point the engine returns 11.2 hr for required replenishment workload time, the number this scenario is built around.
  • At this operating point the engine returns 10 hr for base replenishment workload time.
  • At this operating point the engine returns 12 % for replenishment workload allowance applied.
  • At this operating point the engine returns 12 pieces / min for replenishment workload 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 single steady completion rate; it does not model travel between reserve locations, forklift availability, or bursts where many faces empty at once.

Results at a glance

  • Required replenishment workload time: 11.2 hr (headline result)
  • Base replenishment workload time: 10 hr
  • Replenishment workload allowance applied: 12 %
  • Replenishment workload completion rate: 12 pieces / min

Run it with your numbers

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

Last reviewed 2026-05-12.