Work out pick rate per hour instantly with clear inputs, formula shown and shareable results.
Pick rate is 3,600 divided by the time per pick, multiplied by stations and by effective working time, then reduced by the rework rate. The efficiency factor covers breaks, replenishment waits and micro-stoppages, and it is usually the difference between a quoted rate and an achieved one.
Pick rate
picks/h = (3600 / pick time) x stations x efficiency x (1 - rework rate)
Replenishment, exception handling, breaks and fatigue all consume time. Sustained rates above 85% of theoretical are rare over a full shift.
Only until replenishment, aisle access or the downstream conveyor saturates. Beyond that, throughput plateaus.