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Lines per picker i Average lines picked per picker. The 7-day average is based on the last 7 complete days (excluding today). Target is 600 lines per picker.
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Forklift dependency i Forklift dependency = share of picked lines where a forklift was called. The 7-day average is based on the last 7 complete days (excluding today). Target is to keep dependency at or below 10% to minimize wasted picker time.
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Lost capacity (estimate) i This metric converts forklift waiting time into an equivalent number of full picker shifts. The picker shift length used in the calculation is 10 hours. The goal is to keep lost capacity below 1.0 picker per day.
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Projected lines today i Estimated total fully picked lines by end of day.
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Problem aisles - forklift load i Problem aisles - forklift load

This table shows aisles ranked by how often pickers need a forklift there.

- Lines: number of picked lines in the aisle today

- Forklift calls: number of forklift calls in this aisle- Forklift calls: number of forklift calls in this aisle


- Calls per 100 lines: forklift calls normalized by volume

Use this list to find aisles where popular SKUs sit too high or in blocked locations and are good candidates for rearrangement or extra ground level locations.
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Top SKUs creating forklift load i Top SKUs creating forklift load

This table shows SKUs that generate the most forklift work.

- Lines picked: number of picked lines with this SKU today

- FL calls: forklift calls when picking this SKU

- FL share (%): share of picks that required a forklift

Use this list to find SKUs that are often picked but almost always need a forklift. These SKUs are good candidates to move to lower shelf levels, to closer aisles, or to create a separate ground level forward picking location.
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