Deterministic Baseline
01 · Calculate
Deterministic Engineering Engines
Enter daily volume, assumed process time, roster configuration and current crew. The engine calculates required FTE, available daily volume and exact capacity gaps.
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The Warehouse Engineering Studio
Design warehouse layouts. Diagnose bottlenecks.Deliver boardroom-ready briefs in 2 minutes.
Stop rebuilding fragile spreadsheets the night before an executive review. Model building footprints, SEMA pallet racking, dock hall turnarounds and staffing curves with verified industrial engineering engines.
01 2D CAD Blueprints·02 Bottleneck Audit·03 Boardroom Capex Memos
Interactive Engineering StudioLive CAD
Dynamic Warehouse Blueprint & Sizing
Pallets:
Aisles:
Height:
3,840 m² building · 10.0 m to the eaves
About 92 × 42 m with 8 docks and 12 yard spaces.
- Goods-in / out 259 m²
- Racking 1,973 m²
- Floor stack 608 m²
- Ancillary 1,000 m²
Storage block
2,581 m²
3,600 racked · 900 on the floor
Racking levels
7
3,612 positions
Recommended eaves
10.0 m
Areas are to scale. The arrangement is typical, not a design: the storage block and marshalling area would be laid out around your site.
Gross Footprint
3,840 m²
Building Envelope
92 × 42m
Dock Doors
8 Bay Doors
Storage Density
0.9 m²/pos
Showing real-time engineering geometry · 30 verified modules onlineOpen Full Parameter Workbench
30
Verified calculation engines
Deterministic arithmetic
10
Production Excel templates
Unlocked in toolkit
5
Completed worked cases
Inbound, pick & storage
£79
Lifetime access
One-off payment
60-Second Operational Audit
Warehouse Health Diagnostic & Bottleneck Simulator
Enter your floor parameters below. The diagnostic engine stress-tests labour capacity, dock throughput, and vertical cube to detect hidden margin leakage.
Operating Inputs
Deterministic Engine4,500 units/day
1,000 u/d8,000 u/d15,000 u/d
10 FTE
2 staff20 staff40 staff
7,500 m²
2,000 m²12,000 m²25,000 m²
4 Docks
1 bay8 bays16 bays
Peak Season Stress Test+0% Demand
Simulates Q4 Black Friday or promotional surges without modifying baseline roster.
OPTIMAL: Operation Well-Balanced
Primary Constraint: Balanced
88
Health Score
Out of 100
Labour allocation is running within the optimal ±5% efficiency window.
Labour Load88%
8.8 FTE Req
+1.2 surplus staff
Bay Load25%
9 Trailers/day
Smooth turnaround
Cube Uplift+38%
5.6 m²/unit
VNA headroom
Prioritized Engineering Interventions
01
Model Narrow Aisle (VNA) or High-Density Racking
Your 7,500 m² footprint can yield +38% pallet capacity by migrating wide reach truck aisles (3.0m) to guided VNA (1.8m).
Impact: Defers external 3PL overspill lease commitments.
02
Run Process Cycle-Time Kaizen on Primary Pick Wave
Shaving just 5 seconds off the current 45s cycle time frees up 6.3 daily productive hours.
Impact: Increases throughput headroom without increasing headcount.
Solutions by Operation
Engineering solutions for every warehouse challenge.
Explore the 5 core operational domains. Every engine calculates transparent outputs with published arithmetic identities.
Labour & Capacity
Deterministic staffing curves and shift balancing
Size any warehouse process from observed cycle time or MTM assumptions. Account for rostered hours, productive allowances and shift patterns without burying utilization factors in arbitrary spreadsheet cells.
- Calculates exact net productive shift minutes per FTE
- Separates headcount, overtime and method improvement levers
- Instant scenario generation for peak and off-peak volume waves
Operational Engineering Parameters
Staffing Precision
±0.1 FTE
Sensitivity Range
−20% to +20%
Identity
Deterministic v1.0
Transparent Identity
Outputs are calculated deterministically from standard industrial engineering formulas. All calculations map directly to checked Excel formulas.
What it solves
Still rebuilding the same labour and capacity workbook the night before a review?
The workbench answers four critical operational questions: how many people are needed, what is the throughput capacity, what happens when volume swings, and how to justify it upstairs with boardroom-grade certainty.
Building, racking & docks
Calculate required square meters, pallet rack elevations, dock doors and yard staging buffers before freezing warehouse capital commitments.
Labour, fleet & rate card
Accurately size headcount, MHE fleet and handling cost. Separate human crew, overtime and cycle-time levers with precision.
Briefs you can present
Generate structured management summaries with constraints, data and clear recommendations. Export directly into Excel.
Executive Deliverable Generator
One click to a capex brief that holds in front of the board.
Operations managers and industrial engineers dread writing executive memos for the CFO or Board. Logistics Analyzer generates formal, boardroom-grade engineering memorandums with CAD blueprints, SEMA standards, and sensitivity tables in under two minutes.
- Executive Verdict & Risk Rating: Immediate C-suite bottom line on capex justification and operational risk.
- High-Resolution CAD Blueprint & Elevation: Visual proof of racking, dock hall, and building layout.
- Defensible SEMA & HSE References: Quoting standard industrial codes of practice to defend your assumptions.
- Print / PDF Ready: Formatted for clean A4/Letter handouts or instant copy-to-clipboard for email/Slack.
CONFIDENTIAL // BOARDROOM MEMO
SEMA / UK HSE COMPLIANTSUBJECT: CAPITAL & CAPACITY JUSTIFICATION
STATUS: CAPEX JUSTIFIED · PAYBACK 4.2 MONTHS
• Floor Footprint: 8,400 m² (10m clear eaves)
• Pallet Capacity: 5,420 positions (SEMA APR 500mm top)
• Dock Bay Allocation: 6 doors (92% peak capacity)
• Staffing Curve: 12.4 FTE (±20% surge buffered)
5. SIGN-OFF BLOCK
Lead Logistics Engineer: ________________ Date: ______
Operations Director: ________________ Date: ______
Click to view full interactive memo →
Continuous Engineering Flow
Calculate → Optimise → Report
A continuous, checked workflow designed for industrial operations. Real floor data in, defensible management briefs out.
Scenario Modelling
02 · Optimise
Continuous Sensitivity Levers
Stress-test −20% / +20% demand swings, peak hour surges, dock turnaround, absence buffers and overtime as separate engineering levers.
Defensible Deliverable
03 · Report
Boardroom-Ready Justification
Generate structured management briefs containing the constraint, key metrics and recommendations. Identical mathematical identities across browser and Excel models.
Free Interactive Engine
Warehouse Capacity & FTE Calculator
Enter your shift volume and cycle time. The live engine immediately returns required headcount, available capacity, staffing gap, and a boardroom-ready brief.
Management Brief
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.
Full Engineering Suite
Twenty-five verified calculation engines.
Building footprint, pallet racking, MHE fleet, dock doors, staffing curves and rate cards. Open the full workbench.
Module 11 · BuildingToolkit
Warehouse Building Size
How many square metres to rent or build, from stock, racking, floor stack, goods-in and docks.
Launch Engine
Module 12 · BuildingToolkit
Pallet Racking
SEMA-aligned APR: levels, bays, locations and the floor area for a given building height and truck.
Launch Engine
Module 13 · BuildingToolkit
Floor Storage
Block-stack on the floor: height, lane depth, footprint. For bulk SKUs that must not go into racking.
Launch Engine
Module 14 · BuildingToolkit
Goods-in / Lorry Hall
Marshalling floor from inbound and outbound pallets, plus docks and yard for the lorry fleet.
Launch Engine
Module 16 · BuildingToolkit
Storage Media Selector
APR, double-deep, push-back, drive-in, flow, shuttle, mobile or floor — from SKU depth and FIFO.
Launch Engine
Module 15 · CommercialToolkit
3PL Rate Card
Open-book inbound, storage, pick, pack and outbound rates from weekly volumes and cost.
Launch Engine
Module 19 · CommercialToolkit
Cost to Serve
Allocate warehouse cost to one customer and see if they make money.
Launch Engine
Module 25 · CommercialToolkit
Automation & Capex Payback
Payback, NPV, IRR and the break-even savings a capital request has to survive.
Launch Engine
Module 26 · CommercialToolkit
3PL Contract P&L & Break-even
Year-1 margin, break-even volume, downside and whole-term profit for a bid, with indexation and a volume commitment.
Launch Engine
Module 17 · FleetToolkit
MHE Fleet
How many trucks, batteries and chargers, plus hire versus buy.
Launch Engine
Module 21 · FleetToolkit
Yard / Shunter
Tugs and shunter people from drop-trailer moves, not just yard spaces.
Launch Engine
Free Engine · CapacityFree
Warehouse Capacity & FTE
Required FTE, available capacity and the +20% volume case.
Launch Engine
Module 01 · CapacityToolkit
Warehouse Capacity
Available throughput versus demand, with an explicit planning buffer.
Launch Engine
Module 05 · CapacityToolkit
Shift Capacity
Throughput per shift, day and week from a rostered crew.
Launch Engine
Module 06 · CapacityToolkit
Peak Capacity
What happens when the peak day and peak hour are not the average.
Launch Engine
Module 02 · ManpowerToolkit
FTE Requirement
Direct FTE, absence cover, indirect labour and whether overtime can close the gap.
Launch Engine
Module 03 · ManpowerToolkit
Productivity
Units per hour, earned hours and performance against an assumed time.
Launch Engine
Module 04 · ManpowerToolkit
Utilisation
Separate process utilisation from capacity utilisation.
Launch Engine
Module 18 · ManpowerToolkit
UK Loaded Labour
Holiday, bank holidays, NI, pension and cover — people on the floor versus people on the roster.
Launch Engine
Module 24 · ManpowerToolkit
Pick Rate
Lines per hour and pickers for discrete, batch or zone pick.
Launch Engine
Module 27 · ManpowerToolkit
Peak Labour Mix
Permanent, agency or overtime for the peak. Annual cost of each and how long a peak must last before hiring wins.
Launch Engine
Module 28 · ManpowerToolkit
Time Standard Builder
Turn MTM element times (TMU) into a standard, units per hour, FTE and labour cost per unit.
Launch Engine
Module 07 · InboundToolkit
Dock Capacity
How many vehicles the docks can process, and how many docks you need.
Launch Engine
Module 08 · InboundToolkit
Vehicle Processing
Arrival rate, service rate, peak-hour queue and yard spaces.
Launch Engine
Module 23 · InboundToolkit
UK Trailer Cube
26 UK or 33 Euro on a 13.6 m trailer, or weight-limited, then how many vehicles.
Launch Engine
Module 29 · InboundToolkit
Dock Queue & Wait Time
How long trucks wait at the peak hour, how many docks keep waits inside a target, and what the queue costs.
Launch Engine
Module 09 · StorageToolkit
Storage Capacity
Pallet locations, fill target, location gap and days of cover.
Launch Engine
Module 22 · StorageToolkit
Safety Stock → Space
Max-method safety stock turned into pallets, locations, m² and rent.
Launch Engine
Module 10 · AnalysisToolkit
Capacity Gap
Unit gap, FTE gap, overtime hours or process time needed to close it.
Launch Engine
Module 20 · AnalysisToolkit
ABC Slotting
How many pick hours you save if A-movers sit in the golden zone.
Launch Engine
Operational Case Studies
Completed worked examples, not blank templates.
Study exact worked methodologies. Every case study is built from industrial principles across picking, cross-docking, storage and manpower.
CASE 01
Inbound warehouse
80 vehicles/day through 8 docks.
Open Completed Case
CASE 02Outbound warehouse
Orders through pack and despatch on one page.
Open Completed Case
CASE 03Picking operation
1,000 cases/day at 3 minutes each.
Open Completed Case
CASE 04Vehicle receiving
Arrival rate, occupancy and yard spaces.
Open Completed Case
CASE 05Manpower optimisation
Absence, indirect and overtime as separate levers.
Open Completed Case
Product 1
Warehouse Process Design Toolkit
The complete professional engineering suite. Calculators, spreadsheet packs and worked studies for warehouse capacity, manpower, docks and rate cards.
- 24 paid calculators plus one free: building, rate card, fleet, labour, docks and storage
- 10 industrial process & management presentation templates
- 5 completed end-to-end operational case studies
- Comprehensive formula references and engineering assumptions
- Individual commercial licence for professional client and employer deliverables
Price
£79
Lifetime AccessOne-off payment
Instant Workbench & Excel Access
Lifetime access to all 30 models online. Download the complete matching Excel workbook pack whenever you are ready.
Who It Is For
Built for logistics professionals who need a defensible number.
Design Reviews
Process and industrial engineers
Size a process from observed or assumed time and take a defensible number into a design review with senior engineering leaders.
Daily Operations
Warehouse and operations managers
Instantly see whether today’s crew holds the schedule, and exactly what a 20% volume step or seasonal peak does to the roster.
CI & Kaizen
Continuous-improvement teams
Separate manpower, overtime and process-time levers before you write and submit the capital or Kaizen proposal.
Executive Briefs
Supply-chain and logistics analysts
Turn a complex dock, storage or labour problem into a clean one-page executive brief instead of maintaining fragile ad-hoc workbooks.
Transparency & Methodology
Engineered from real operational practice.
Real Operations Experience
Built from years of operational design: high-bay VNA, reach trucks, MTM predetermined time methods, shift balancing and 5S logistics engineering.
Published Open Arithmetic
Every engine ships with clear mathematical identities, boundary limits and test cases. Fully checked against extreme and edge parameters.
10 Production Templates
Pre-built executive brief templates, Kaizen proposals, operational audit checklists and rate card models ready to present.
Process MapStandard WorkWork ContentManpower CalculationCapacity AnalysisBottleneck AnalysisExplore all 10 templates →
Immediate Operational Readiness
Two minutes to a staffing number that holds in a meeting.
Start with the free calculator right now, or unlock all 30 engines and 10 production templates with the toolkit licence.