One shift through pick, takeaway conveyor, put wall and pack. Change any input and watch where the building backs up. Sample data.
Orders per hour. When the red area opens up, orders are arriving faster than the building ships them, and the backlog grows.
What happened, and when.
Orders received but not started. Grows when the wall has no free cells.
Cells in use (blue), and how many hold finished orders waiting for pack (amber). Dashed line is capacity.
Totes on the takeaway and waiting to induct. At the dashed line, pickers can't drop totes.
Bars show utilization over the last 10 minutes; "avg" is the shift so far.
In a one-week operations review I load your real orders, rates and staffing, calibrate the model against a real day, and walk the floor to find out why it breaks.