Work Throughput Capacity for 100% Inspection and Packing
Models an operational team of 4 inspection operators and 1 assistant.
Required work space expands or contracts based on roll-box cart dimensions and operational methods.
Calculation Example:
Executing 100% inspection on 20,000 piece items per hour.
Processing rate = 2.0 seconds per inspected piece item.
1 set of 4 operators processes 1 piece item every 0.5 seconds.
Hourly processing capacity per set = 3,600 / 0.5 = 7,200 pieces.
Required sets = 20,000 / 7,200 = 2.8 sets => 3 sets.
Required area = 13 m² * 3 sets = 39 m².
Section 10 Inspection & Packing Calculation: 100% Inspection and Outbound Work Area Design
Two Calculation Models in Inspection & Packing Operations
Depending on the required strictness of outbound operations and automation levels, required installation floor areas for inspection and packing are derived using two distinct approaches:
- Inspection & Packing Calculation 1 (100% Inspection Model): A standard operational model executing thorough 100% inspection and packing for all outbound items.
- Inspection & Packing Calculation 2 (Inspection-less Model): An optimized, "inspection-less" outbound work flow based on Chapter 4 Distribution Center Scale Calculations.
Subsection 1: Inspection & Packing Calculation 1 (100% Inspection Standard Model)
This model derives the required work set count and floor area for 100% inspection and packing based on staffing headcounts and processing throughput rates.
Workforce Configuration and Floor Area Principles
- Standard Team Setup: Models 1 work set team comprising 4 inspection operators and 1 assistant (5 staff total).
- Variable Parameters: Required work space expands or contracts based on roll-box cart dimensions and actual outbound work flow procedures.
Calculation Simulation Example (100% Inspection)
Example calculation for performing 100% inspection and packing on 20,000 piece items per hour:
| Parameter Item | Numerical Value |
|---|---|
| Inspection Time per Piece Item | 2.0 seconds |
| Set Throughput Capacity (4 Operators) | 7,200 pieces / hour (3,600 sec / 0.5 sec) |
| Required Work Set Count | 3 Sets (20,000 / 7,200 ＝ 2.77…) |
| Total Required Area | 39 m² (13 m² × 3 Sets) |
Subsection 2: Inspection & Packing Calculation 2 (Inspection-less & Outbound Efficiency Model)
Models layout optimization for outbound work floor space and traffic lines by streamlining or automating inspection processes.
- System Integration: Dynamically links with piece picking flow diagrams established in Chapter 4 Distribution Center Scale Calculations.
- Multi-Set Configurations: For high-throughput volumes, simulates overall layout area when deploying multiple packing and work lines (sets).
Subsection 1 Inspection & Packing Calculation 1 Screen
Inspection & Packing Calculation 1 assumes 100% inspection and packing operations, while Calculation 2 models the inspection-less outbound work flow adopted in Tera Calculation (Distribution Center Scale Calculation).
For details on inspection-less outbound work flows, refer to "Chapter 4 Tera Calculation 2 Automated: Subsection
7 Inspection, Packing & Piece Picking Flow Diagram".
Inspection & Packing Area Calculation for Multi-Set Layouts
Displays layout floor area calculations for outbound work, inspection, and packing spaces when deploying multiple work sets.
Subsection 2 Inspection & Packing Calculation 2 Screen
Inspection & Packing Calculation 2 Concept
Displays conceptual lines for outbound work and packing in inspection-less operational models.
Example layout arrangement for outbound work lines deployed across multiple sets.