Consultants in Lean Manufacturing Á Manufacturing Strategy

Consultants in Lean Manufacturing & Manufacturing Strategy

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Books & Videos

The Strategos Guide To Value Stream and Process Mapping goes far beyond symbols and arrows. In over 163 pages it tells the reader not only how to do it but what to do with it. More info...

Strategos Guide to Value Stream & Process Mapping

Also...

Guide to Cycle Counting

Facilities & Workplace Design

Warehouse Planning Guide

Human Side of Lean Video

Rackable Item Standard Pick Times

Stored on pallets; Picked by Item or Case

Rackables Work times on this page are for warehouses or warehouse modules in which pallets are stored on racks an picked by case or item directly from the pallet. Table 1 shows times and components for a warehouse or module of 2000 pallets. For larger or smaller warehouses, table 2 extends the total time found in table 1.

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Time values come from the Warehouse Modernization & Layout Planning Guide, NS529. They were derived using a pre-determined time system (probably MTM). They are reasonably accurate for the purposes specified.

The spreadsheets on these pages are available as a free download in xls format. Just click below...

Staff Planning
Warehouse Design
Equipment Selection
General Benchmarking
Estimating Operating Cost

Do Not Use For:

Employee Performance Evaluation
Daily/Weekly Performance Evaluation

AVERAGE RACKABLES ORDER PICKING TRANSACTION TIME
(Minutes per Line Item Issue Including 20% Personal Fatigue and Delay Allowance)
(Based on Average Inventory of 2,000 Pallet Positions per Order Picking Module)
	System	Storage Levels	Density Factor	Average Height	Travel Time	Maneuver Time	Pick/ Document Time	Lift/ Lower Time	Replenish/ Document Time	Misc. Time	Total Time
	Order Picking Truck	2	0.86	4.0	1.977	0.544	1.356	0.057	0.048	0.028	4.010
		3	1.30	6.0	1.388	0.386	1.356	0.083	0.048	0.028	3.289
		4	1.73	8.0	1.101	0.309	1.356	0.108	0.048	0.028	2.951
		5	2.16	10.0	0.929	0.263	1.356	0.134	0.048	0.028	2.758
	Man-Up Turret Truck	4	1.73	8.0	0.450	0.195	1.320	0.143	0.028	0.074	2.212
		5	2.16	10.0	0.381	0.162	1.320	0.192	0.028	0.074	2.157
		6	2.59	12.0	0.335	0.139	1.320	0.240	0.028	0.074	2.136
		7	3.03	14.0	0.301	0.122	1.320	0.288	0.028	0.074	2.134
		8	3.46	16.0	0.277	0.110	1.320	0.336	0.028	0.074	2.145
		9	3.89	18.0	0.258	0.100	1.320	0.384	0.028	0.074	2.165
		10	4.32	20.0	0.242	0.093	1.320	0.432	0.028	0.074	2.190
	Hybrid Truck	7	3.00	14.5	0.255	0.074	1.320	0.000	0.028	0.074	1.752
		8	3.43	16.5	0.245	0.068	1.320	0.000	0.028	0.074	1.736
		9	3.86	18.5	0.238	0.063	1.320	0.000	0.028	0.074	1.724
		10	4.29	20.5	0.233	0.060	1.320	0.000	0.028	0.074	1.715
		11	4.71	22.5	0.230	0.057	1.320	0.000	0.028	0.074	1.709
		12	5.14	24.5	0.228	0.054	1.320	0.000	0.028	0.074	1.705
		13	5.57	26.5	0.227	0.052	1.320	0.000	0.028	0.074	1.702
		14	6.00	28.5	0.227	0.050	1.320	0.000	0.028	0.074	1.700
		15	6.43	30.5	0.227	0.048	1.320	0.000	0.028	0.074	1.698
		16	6.86	32.5	0.228	0.047	1.320	0.000	0.028	0.074	1.698
	Manned S/R Machine	10	4.32	20.5	0.441	0.026	1.320	0.016	0.028	0.074	1.905
		11	4.76	22.5	0.407	0.026	1.320	0.016	0.028	0.074	1.872
		12	5.19	24.5	0.381	0.026	1.320	0.016	0.028	0.074	1.846
		13	5.62	26.5	0.359	0.026	1.320	0.016	0.028	0.074	1.824
		14	6.05	28.5	0.341	0.026	1.320	0.016	0.028	0.074	1.806
		15	6.49	30.5	0.326	0.026	1.320	0.016	0.028	0.074	1.790
		16	6.92	32.5	0.313	0.026	1.320	0.016	0.028	0.074	1.778
		17	7.35	34.5	0.302	0.026	1.320	0.016	0.028	0.074	1.767
		18	7.78	36.5	0.293	0.026	1.320	0.016	0.028	0.074	1.758
		19	8.22	38.5	0.285	0.026	1.320	0.016	0.028	0.074	1.750
		20	8.65	40.5	0.279	0.026	1.320	0.016	0.028	0.074	1.743

RACKABLES ORDER PICKING STANDARD TRANSACTION TIME
(Minutes per Line Item Issue Including 201 Personal Fatigue and Delay Allowance)
	System	Pick Area Inventory in Pallet Positions
	System	Storage Levels	100	300	500	1,000	1,500	2,000	3,000	4,000	5,000	6,000	7,000	8,000	9,000	10,000
	Order Picking Truck	2	1.912	2.133	2.354	2.906	3.458	4.010	5.114	6.219	7.323	8.427	9.531	10.635	11.740	12.844
		3	1.901	2.047	2.192	2.558	2.923	3.289	4.019	4.749	5.480	6.210	6.941	7.671	8.402	9.132
		4	1.908	2.018	2.128	2.402	2.677	2.951	3.500	4.049	4.598	5.147	5.696	6.244	6.793	7.342
		5	1.923	2.011	2.099	2.318	2.538	2.758	3.198	3.637	4.077	4.517	4.956	5.396	5.835	6.275
	Man-Up Turret Truck	4	1.719	1.771	1.823	1.953	2.082	2.212	2.472	2.731	2.990	3.250	3.509	3.769	4.028	4.288
		5	1.762	1.804	1.845	1.949	2.053	2.157	2.365	2.573	2.780	2.988	3.196	3.404	3.611	3.819
		6	1.807	1.842	1.876	1.963	2.050	2.136	2.309	2.483	2.656	2.829	3.003	3.176	3.349	3.522
		7	1.853	1.882	1.912	1.986	2.060	2.134	2.282	2.430	2.578	2.726	2.875	3.023	3.171	3.319
		8	1.899	1.925	1.951	2.016	2.080	2.145	2.275	2.405	2.534	2.664	2.794	2.924	3.053	3.183
		9	1.946	1.969	1.992	2.049	2.107	2.165	2.280	2.396	2.511	2.626	2.742	2.857	2.972	3.088
		10	1.993	2.013	2.034	2.086	2.138	2.190	2.294	2.398	2.502	2.606	2.709	2.813	2.917	3.021
	Hybrid Truck	7	1.600	11.616	1.632	1.672	1.712	1.753	1.833	1.914	1.995	2.075	2.156	2.237	2.317	2.398
		8	1.603	1.617	1.631	1.666	1.701	1.737	1.807	1.878	1.948	2.019	2.089	2.160	2.230	2.301
		9	1.606	1.618	1.631	1.662	1.694	1.725	1.788	1.850	1.913	1.976	2.038	2.101	2.164	2.226
		10	1.609	1.620	1.631	1.660	1.688	1.716	1.772	1.828	1.884	1.940	1.996	2.052	2.108	2.164
		11	1.613	1.623	1.633	1.659	1.685	1.710	1.762	1.813	1.864	1.916	1.967	2.019	2.070	2.121
		12	1.616	1.625	1.635	1.658	1.681	1.705	1.751	1.798	1.845	1.891	1.938	1.985	2.031	2.078
		13	1.620	1.629	1.637	1.659	1.681	1.702	1.746	1.789	1.833	1.876	1.920	1.963	2.007	2.050
		14	1.624	1.632	1.640	1.660	1.680	1.700	1.740	1.780	1.820	1.860	1.900	1.940	1.980	2.020
		15	1.628	1.635	1.642	1.661	1.680	1.699	1.736	1.774	1.812	1.849	1.887	1.925	1.962	2.000
		16	1.631	1.638	1.645	1.663	1.680	1.697	1.732	1.767	1.802	1.837	1.872	1.907	1.942	1.977
	Manned S/R Machine	10	1.522	1.562	1.603	1.703	1.804	1.905	2.107	2.308	2.510	2.712	2.913	3.115	3.317	3.518
		11	1.524	1.561	1.597	1.689	1.780	1.872	2.055	2.238	2.421	2.604	2.787	2.970	3.153	13.336
		12	1.527	1.560	1.594	1.678	1.762	1.846	2.013	2.181	2.349	2.517	2.865	2.853	3.021	3.188
		13	1.529	1.560	1.591	1.669	1.746	1.824	1.979	2.134	2.289	2.444	2.599	2.754	2.909	3.064
		14	1.532	1.561	1.590	1.662	1.734	1.806	1.950	2.094	2.238	2.382	2.526	2.670	2.114	2.958
		15	1.535	1.562	1.589	1.656	1.723	1.709	1.925	2.059	2.193	2.327	2.461	2.596	2.730	2.864
		16	1.538	1.564	1.589	1.652	1.715	1.778	1.904	2.029	2.155	2.281	2.407	2.533	2.659	2.785
		17	1.540	1.563	1.587	1.646	1.706	1.765	1.883	2.002	2.121	2.239	2.358	2.476	2.595	2.713
		18	1.545	1.567	1.590	1.646	1.702	1.758	1.870	1.982	2.094	2.206	2.318	2.430	2.542	2.654
		19	1.548	1.570	1.591	1.644	1.697	1.750	1.856	1.962	2.068	2.174	2.280	2.386	2.492	2.598
		20	1.552	1.572	1.592	1.643	1.693	1.743	1.844	1.945	2.043	2.146	2.247	2.348	2.448	2.549