Free warehouse planning tool

Estimate staging positions from the work moving through each zone.

Turn a comparable busy-period flow rate and observed dwell time into a position estimate. Keep exception holds separate when they behave like inventory rather than a steady flow.

Map the concurrent staging flows

For a flow that is absent, leave its rate at 0. Use a comparable busy period and include only flows that can occupy this area at the same time.

Receiving

Arrivals waiting for receiving, inspection, or putaway.

Position-equivalents entering per hourIf one load uses multiple floor positions, enter position-equivalents rather than load count.Average minutes in this zoneMeasure from arrival in this zone to the next move or decision.

Estimated positions: 0 positions

Outbound

Picked orders waiting for loading or carrier handoff.

Estimated positions: 0 positions

Cross-dock

Loads waiting for a direct transfer to the next outbound move.

Estimated positions: 0 positions

Quality / exception holds

Enter the observed peak count directly when hold dwell is long or uncertain. Do not also count these loads in another row.

Peak occupied positions

Combined estimated positions

0 positions

Usable marked positions in the shared area (optional)

The calculation runs in this page. Values you enter are not submitted to Sizelabs.

How to use the estimate

Use a busy-period snapshot, not daily volume

For a flow that moves through staging at a reasonably steady rate, estimate simultaneous positions as position-equivalents entering per hour × average minutes in the zone ÷ 60, rounded up to a whole position. Add the flows only when they can occupy the shared area at the same time.

Example: 12 position-equivalents per hour × 15 minutes ÷ 60 = 3 positions. This is an arithmetic illustration, not a warehouse benchmark or a safe-layout recommendation.

Scope

What this estimate leaves out

Use position-equivalents per hour when a load takes more or less than one marked floor position.
Do not count the same handling unit in two rows for the same snapshot. For quality or exception holds with long or uncertain dwell, enter the observed peak positions directly.
The result does not design aisles, clearances, egress, rack capacity, dock schedules, or fire-safe layouts. Confirm those with the responsible facility and safety professionals.

Next operating step

Use the next page that fits the operating question.

Read the staging flow guide

Separate concurrent work by purpose and define the next move before adding floor positions.

Open the staging guide →

Plan an operating pilot

Turn a real freight mix, control, and review owner into a field-test brief.

Open the pilot planner →

FAQ

Questions about staging positions

What does a staging capacity estimate mean?

It is a planning estimate of the number of marked floor positions occupied by the flows and hold inventory you entered during a comparable busy period. It is not an engineered or safety capacity limit.

Why enter exception holds separately?

A held load may remain in place for an uneven or unknown time, so an average arrival rate can understate the peak. Use the observed number of positions occupied at the same time.

Are the values I type sent to Sizelabs?

No. The calculation runs in this page, and the entered values are not submitted to Sizelabs.

Use a busy-period snapshot, not daily volume

Example: 12 position-equivalents per hour × 15 minutes ÷ 60 = 3 positions. This is an arithmetic illustration, not a warehouse benchmark or a safe-layout recommendation.