Order Picking Productivity Calculator

Which metric should I use to evaluate picker performance?

Lines-per-hour is generally the most stable and fair metric because it normalizes for order size without being distorted by bulk single-line orders the way units-per-hour can be. Use units-per-hour as a secondary check when comparing periods with very different average pick quantities per line, like a promotional period with case-pick orders.

How do I set a fair productivity standard?

Time-study your own top-quartile performers over several weeks rather than importing an industry benchmark, since travel distance, SKU mix, and pick method (each vs. case vs. pallet) vary enormously between facilities. A standard set from your own data, adjusted for your specific layout, holds up much better under grievance or performance review scrutiny.

Why did units-per-hour drop while lines-per-hour stayed flat?

This usually signals a shift toward smaller quantity-per-line orders — for example a promotional period driving many single-unit orders instead of case-pack orders. It's not necessarily a productivity problem; check unit-per-line trend before concluding pickers slowed down.

Does this account for non-productive time like breaks and staging?

No — hours worked here should be net productive picking time if you want a true rate, or gross clocked hours if you want a fully loaded operational rate that includes breaks, meetings, and staging delays. Track both separately; the gap between them is a visibility metric on how much of the shift is actually spent picking.