What this calculator solves
Use Order Packing Time to schedule a defined batch of orders from one setup period and a representative per-order time. It estimates elapsed labor minutes for the batch. Labor Capacity per Shift reverses the question by estimating how many orders fit into available labor.
How to choose the inputs
Count orders using a comparable pack method, measure hands-on minutes across normal operators and order variation, and enter setup only once for the batch. Keep long exceptions separate or use a weighted average supported by observed mix.
| Input | How to prepare it |
|---|---|
| Orders to pack | Order Packing Time Calculator: Count orders to pack in the exact operating unit shown on the dispatch or inventory record; do not mix eaches, packs, cases, or layers. |
| Minutes per order | Order Packing Time Calculator: Time minutes per order across representative normal work and separate setup, exceptions, and breaks unless the definition includes them. |
| Setup minutes | Order Packing Time Calculator: Time setup minutes across representative normal work and separate setup, exceptions, and breaks unless the definition includes them. |
How the calculation works
- Validate the Order Packing Time Calculator manifest: confirm that orders to pack, minutes per order, setup minutes describe the same Order Packing Time Calculator pack, batch, or planning period.
- Calculate batch duration: apply Total time = setup minutes + orders × minutes per order without rounding intermediate values for Order Packing Time Calculator.
- Review the batch duration breakdown: use the primary result for the stated decision and the secondary values to identify the input or constraint driving this Order Packing Time Calculator result.
Worked example
A 120-order run at 3.5 minutes each plus 20 minutes setup takes 440 minutes.
Next action: After: compare required minutes with shift capacity and investigate the main time element.
How to interpret the result
Use total minutes for release scheduling and average minutes per order for process comparison. If setup is a large share, larger batches may improve efficiency; if run time dominates, focus on motion, material staging, and pack design. Include verification steps in the observed method.
Common mistakes
- Using the single fastest cycle as the standard.
- Multiplying setup time by every order.
- Mixing simple and complex orders without recording the mix.
- Excluding normal checks and replenishment from the defined process.
Assumptions and limitations
The estimate assumes a stable average pace and one setup event. It excludes breaks, absenteeism, equipment failure, queueing, training, unusual exceptions, and learning effects unless represented in the inputs.
Related workflow
- Before: define the process boundary and time a representative sample.
- After: compare required minutes with shift capacity and investigate the main time element.