Return processing capacity calculator

Calculate worker-hours by stage and nominal bottleneck returns per hour with your own figures.

Your numbers

Use the units shown. Results update as you change valid inputs.

Use worker-hours by stage and nominal bottleneck returns per hour to compare changes to your inputs. The method and limits below explain the scope.

Examples

Examples

Try the starting example

Returns
120
Handling minutes per return by stage
2,3
Workers assigned by stage
1,2
Shift hours
4
Worker-hours by stage
4, 6
Nominal bottleneck returns per hour
30
Workload lower bound (hours)
4
Bottleneck stage number
1
Steady-state shift capacity
120

Try another scenario

Returns
60
Handling minutes per return by stage
2,4
Workers assigned by stage
2,1
Shift hours
8
Worker-hours by stage
2, 4
Nominal bottleneck returns per hour
15
Workload lower bound (hours)
4
Bottleneck stage number
2
Steady-state shift capacity
120
Calculation method

Calculation method

Worker-hours by stage

Returns × minutes per return / 60, for each stage.

Nominal bottleneck returns per hour

Minimum of 60 × stage workers / handling minutes across stages.

Workload lower bound (hours)

Returns / bottleneck hourly capacity.

Bottleneck stage number

One-based position of the first stage with the lowest hourly capacity.

Steady-state shift capacity

Floor(bottleneck hourly rate × shift hours), before startup and end-of-shift effects.

Symbols and units
a
Returns
b
Handling minutes per return by stage
c
Workers assigned by stage
d
Shift hours

Use the units shown. A list keeps the order in which you enter its values. The symbol ^ means “raised to the power of”.

Assumptions & limits

Assumptions & limits

  • Steady-state capacity and workload lower bound only. Stage startup, queues and indivisible items increase actual completion time. Shift hours are a planning input; this model does not schedule staff.
Are these inputs private?

These calculations run in your browser. A shared link contains the values you choose to share. Only questions submitted to the separate AI finder are sent to OpenAI.

Further reading

OpenStax: ratios, percentages and rectangular geometry ↗

Background reading; this does not imply endorsement or independent review of SumFizz.

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