01 Calculate
Enter volume, process time, roster and current resources. The engine returns required FTE, available capacity and the gap.
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Warehouse process-engineering workbench
Calculate labour and capacity. Optimise the gap. Report a number that holds in a meeting.
Logistics Analyzer is not a course and not a blank spreadsheet. It is a checked process-design workbench for warehouse engineers, operations managers and continuous-improvement teams.
- 01 Calculate
- 02 Optimise
- 03 Report
Live model · Capacity & FTE
Short 1.84 FTE for 1,000 units/day
Capacity utilisation130.7%
Required FTE
7.84
Available
765/d
Gap
1.84 FTE
Low
6.27
Base
7.84
High
9.41
Default picking case from the live engine — 1,000 units/day, 3.00 min, 6 FTE.
25
Checked calculators
10
Process templates
5
Worked examples
£49
Founding licence
What it does
Still rebuilding the same labour and capacity workbook the night before the meeting?
The product answers four questions: how many people, how much capacity, what happens if volume moves, and how you show that to management. It does not pretend to be a WMS, a digital twin, or an engineering certificate.
The work
Calculate → Optimise → Report
One visual story, tied to the actual product. Photography of the operation; numbers from the engine.
02 Optimise
Test −20% / +20% volume, peak hours, docks, absence and overtime as separate levers — not one buried utilisation factor.
03 Report
Copy a management brief with the number, the constraint and the recommendation. Same identities in the browser and in Excel.
01
Input data
Volume, time, roster, utilisation, current FTE.
02
Calculation
Published identities. Same result every time.
03
Analysis
Utilisation, gap, warnings, peak and buffer views.
04
Optimisation
People, overtime or process-time levers.
05
Scenarios
Low / base / high volume on the same model.
06
Management report
Headline, numbers, recommendation, caveat.
Free model
Warehouse Capacity & FTE Calculator
Enter operating parameters. Get required FTE, available capacity, the capacity gap and a short management brief. The same identities power the Excel download.
Management brief
Presentable output
Short 1.84 FTE for 1,000 units/day
Work content is 3,000 minutes/day (1,000 units × 3.00 min). Each FTE has 382.5 productive minutes per shift after a 85.0% planned-utilisation allowance. Required labour is 7.84 FTE (round up to 8 if you cannot staff fractions).
- Available capacity at 6.00 FTE is 765 units/day.
- Capacity utilisation is 130.7%.
- Capacity gap is 235 units/day. Additional resources required: 1.84 FTE.
- If volume rises 20% to 1,200 units/day, required labour becomes 9.41 FTE.
- If volume falls 20% to 800 units/day, required labour becomes 6.27 FTE.
- Theoretical maximum at 100% utilisation is 900 units/day. That is a ceiling, not a target.
Decision-support only. Validate assumptions before using these figures for staffing or investment decisions.
Capabilities
Twenty-five models. One workbench.
Building, racking, rate card, fleet, labour, docks and storage. One calculator is free. The rest unlock on the website after purchase.
11 · Building
ToolkitWarehouse Building Size
How many square metres to rent or build, from stock, racking, floor stack, goods-in and docks.
12 · Building
ToolkitPallet Racking
SEMA-aligned APR: levels, bays, locations and the floor area for a given building height and truck.
13 · Building
ToolkitFloor Storage
Block-stack on the floor: height, lane depth, footprint. For bulk SKUs that must not go into racking.
14 · Building
ToolkitGoods-in / Lorry Hall
Marshalling floor from inbound and outbound pallets, plus docks and yard for the lorry fleet.
16 · Building
ToolkitStorage Media Selector
APR, double-deep, push-back, drive-in, flow, shuttle, mobile or floor — from SKU depth and FIFO.
15 · Commercial
Toolkit3PL Rate Card
Open-book inbound, storage, pick, pack and outbound rates from weekly volumes and cost.
19 · Commercial
ToolkitCost to Serve
Allocate warehouse cost to one customer and see if they make money.
17 · Fleet
ToolkitMHE Fleet
How many trucks, batteries and chargers, plus hire versus buy.
21 · Fleet
ToolkitYard / Shunter
Tugs and shunter people from drop-trailer moves, not just yard spaces.
Free · Capacity
OpenWarehouse Capacity & FTE
Required FTE, available capacity and the +20% volume case.
01 · Capacity
ToolkitWarehouse Capacity
Available throughput versus demand, with an explicit planning buffer.
05 · Capacity
ToolkitShift Capacity
Throughput per shift, day and week from a rostered crew.
06 · Capacity
ToolkitPeak Capacity
What happens when the peak day and peak hour are not the average.
02 · Manpower
ToolkitFTE Requirement
Direct FTE, absence cover, indirect labour and whether overtime can close the gap.
03 · Manpower
ToolkitProductivity
Units per hour, earned hours and performance against a standard.
04 · Manpower
ToolkitUtilisation
Separate process utilisation from capacity utilisation.
18 · Manpower
ToolkitUK Loaded Labour
Holiday, bank holidays, NI, pension and cover — people on the floor versus people on the roster.
24 · Manpower
ToolkitPick Rate
Lines per hour and pickers for discrete, batch or zone pick.
07 · Inbound
ToolkitDock Capacity
How many vehicles the docks can process, and how many docks you need.
08 · Inbound
ToolkitVehicle Processing
Arrival rate, service rate, peak-hour queue and yard spaces.
23 · Inbound
ToolkitUK Trailer Cube
26 UK or 33 Euro on a 13.6 m trailer, or weight-limited, then how many vehicles.
09 · Storage
ToolkitStorage Capacity
Pallet locations, fill target, location gap and days of cover.
22 · Storage
ToolkitSafety Stock → Space
Max-method safety stock turned into pallets, locations, m² and rent.
10 · Analysis
ToolkitCapacity Gap
Unit gap, FTE gap, overtime hours or process time needed to close it.
20 · Analysis
ToolkitABC Slotting
How many pick hours you save if A-movers sit in the golden zone.
Worked examples
Completed cases, not blank templates
Copy the method. Every case is anonymised and rebuilt from general principles — inbound docks, outbound pack, picking, receiving and manpower.
01
Inbound warehouse
80 vehicles/day through 8 docks.
Open the case02
Outbound warehouse
Orders through pack and despatch on one page.
Open the case03
Picking operation
1,000 cases/day at 3 minutes each.
Open the case04
Vehicle receiving
Arrival rate, occupancy and yard spaces.
Open the case05
Manpower optimisation
Absence, indirect and overtime as separate levers.
Open the caseProduct 1 · founding offer
Warehouse Process Design Toolkit
Calculators, templates and completed examples for capacity, manpower, inbound, outbound and management justification. Founding price for the first 25 customers.
- 24 paid calculators plus one free: building, rate card, fleet, labour, docks and storage
- 10 process and management templates
- 5 completed worked examples
- Formula reference and assumptions guide
- Individual licence for your own professional work
Founding price
£49
Then
£79
Who it is for
Built for people who already have a number to defend
Process and industrial engineers
Size a process from observed or standard time and take a defensible number into a design review.
Warehouse and operations managers
See whether today’s crew holds the day, and what a 20% volume step does to the roster.
Continuous-improvement teams
Separate people, overtime and process-time levers before you write the kaizen proposal.
Supply-chain and CI analysts
Turn a dock, storage or labour question into a one-page brief instead of another ad-hoc workbook.
Why this is not a course
Methodology you can inspect
Process MapStandard WorkWork ContentManpower CalculationCapacity AnalysisBottleneck AnalysisAll 10 templates
Start with the free model
Two minutes to a staffing number you can take upstairs.
Then unlock the rest of the workbench when you need docks, peak hour, absence cover or a management proposal template.