Our Pick and Pack Line Can't Keep Up
A pick and pack line is a line like any other: each station has a cycle time, and the slowest one sets the output. The usual answer is more people everywhere. Takt and a station-by-station balance put them where the line needs them.
What Is Usually Going On
- Staffing is set for average volume, and peak hours run over takt.
- One station, often pack, label or a manual induct, carries more work than the rest.
- Pick paths are long because slotting does not match the current fast movers.
- Order mix shifts the work per station: single-line and large multi-line orders take very different time.
- Cartons, labels and replenishment run out at the station during peak.
How to Fix It
- Set takt for the peakTakt = available minutes in the peak window / units or orders due in that window. Plan to the peak, not the daily average.
- Measure each stationTime ten or more cycles per station and convert to units per hour, with the order mix noted.
- Stack it against taktPlot work content per station on a yamazumi. Stations over takt set the line rate.
- Cut, then move workCut walking and searching at the heavy station first, then shift elements from heavy stations to light ones.
- Re-slot fast moversPut the fastest-moving items in the closest, easiest pick faces. Re-check slotting as the mix changes.
- Staff to the profileHeads per station = work content per unit / takt, by hour of the day. Move flex labor to the heavy station at peak.
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Common Questions
Does takt apply in a warehouse?
Yes. Any flow with a demand rate and set hours has a takt. In a warehouse it is usually set per peak window or per carrier cut-off.
Units per hour or orders per hour?
Use whichever drives the work at that station. Pick time follows lines and units; pack time often follows orders and cartons.
Will automation fix it?
Only at the station it replaces, and only if that station is the slow one. Balance the manual line first so you know the rate the automation has to hit.