How to Calculate Throughput & Improve it with AS/RS

Key takeaways

• Use the formula: Throughput = Total units processed ÷ Time period to measure your output in real time.
• Focus on pick rate, order cycle time, and inventory turnover to spot inefficiencies and boost productivity.
• Manual picking, poor layout, and system delays hurt throughput but smart tech like AS/RS can solve them.
• AS/RS system from AutoStore reduces errors, increases throughput, and makes better use of your space.
• Connecting AutoStore with your WMS, TMS, and ERP gives you live data and full control over fulfillment operations.

How to calculate warehouse throughput in real time

If you want to improve your warehouse performance, you need to measure it first. Throughput is what gives you that visibility and it tells you how many units your operation can process in a given period. The higher the throughput, the more efficient your fulfillment process.

Let’s start with the basic formula:

Throughput = Total units processed ÷ Time period

An example

Imagine your warehouse ships 4,000 items during an 8-hour shift. Here’s how that breaks down:

4,000 units ÷ 8 hours = 500 units/hour

That means your warehouse throughput is 500 units per hour—an essential metric for understanding your capacity and planning labor, inventory, and automation needs.

What about net throughput?

Real-world operations aren’t always smooth. Net throughput accounts for:

• Equipment downtime
• System delays
• Human error
• Defective or returned items

If 300 of those 4,000 items were mispicked or delayed, your net throughput would be:

(4,000 - 300) ÷ 8 hours = 462.5 units/hour

This adjusted view helps you spot gaps and bottlenecks in your workflow.

Throughput vs. performance: What’s the difference?

➔ Throughput measures output quantity: how many units flow through your system.

➔ Performance measures how well your system operates: speed, accuracy, consistency, and cost-efficiency.

You can have high throughput with poor performance (e.g., lots of errors), and vice versa. Ideally, both metrics should improve together.

How to calculate request throughput

Request throughput tracks how many order requests your system can process in a given timeframe. This is especially relevant for B2C e-commerce operations handling high order volumes.

Formula:

Request throughput = Total order requests processed ÷ Time period

If your system processes 2,400 orders during a 12-hour window, your request throughput is 200 orders/hour.

Measuring throughput as a KPI

Warehouse throughput is often used as a key performance indicator (KPI) for:

• Tracking fulfillment speed
• Benchmarking productivity
• Supporting labor and staffing decisions
• Planning system upgrades or automation investments

To get a meaningful throughput KPI, measure consistently and compare over time: daily, weekly, or by shift. Trends matter more than a single number.

Quick throughput formula recap

• Basic throughput = Units processed ÷ Time
• Net throughput = (Units processed - losses) ÷ Time
• Request throughput = Order requests ÷ Time
• Use these to benchmark output, efficiency, and workflow issues.

Tip! Read more about Automated Order Processing.

Knowing how to calculate throughput is just the first step. An important question you should ask is what should you be measuring? And which technologies can help you track throughput in real time? We’ll dig deeper into this in the next section.

What are the most important KPIs and tools for measuring warehouse throughput?

Tracking your throughput is one thing, measuring it with the right tools and metrics is what drives real improvement. We have summarized key KPIs, tools and why they matter for throughput in the table below:

Up next, let’s talk about what happens when throughput breaks down and why speed is mission-critical in e-commerce.

Why real-time tracking makes all the difference

Measuring throughput in real time allows you to:

• React instantly to slowdowns or delays
• Allocate labor and equipment more effectively
• Adjust workflows before they impact delivery times
• Improve forecasting for peak periods and promotions

More importantly, it puts you in control. Instead of waiting for end-of-day reports, you can make decisions while they still matter, leading to higher efficiency and a better customer experience.

Now that you know which KPIs and tools can help you measure and manage throughput, the next question is: what happens when those numbers start to slip? Let’s explore why consistent, high-speed throughput has become business-critical.

Why fast throughput is non-negotiable in e-commerce fulfillment

In e-commerce, fast delivery isn’t a perk, it’s expected. And if your warehouse can’t keep up, the consequences add up fast.

The real cost of falling behind

Slow or inconsistent throughput leads to:

• Missed service-level agreements (SLAs) and contract penalties
• Late deliveries that frustrate customers
• Stockouts and delayed replenishment
• Lost loyalty when shoppers turn to faster competitors

It’s not just about money, it’s also operational strain. Teams rush, errors rise, and service quality dips.

Throughput powers scalable growth

When your turnaround times are fast and reliable, you can:

• Manage peak periods without chaos
• Launch new SKUs or sales channels smoothly
• Scale without adding unnecessary complexity

In short, throughput fuels both speed and stability.

And the best part? You don’t have to sacrifice your team to achieve it. With automation, scaling throughput becomes smarter, not harder.

So, what usually gets in the way? Let’s look at the most common bottlenecks that hold throughput back and how to fix them.

How to fix 5 common bottlenecks that reduce throughput

Even top-performing warehouses face slowdowns. The key is knowing where they happen and fixing them fast. Here are five common throughput blockers and how to solve them:

• Manual picking and long travel times:
  ‍When workers walk too much, efficiency drops.
  -> Fix: Switch to goods-to-person automation like AS/RS to cut travel time and boost accuracy.
• Poor warehouse layout:
  Cluttered paths and disorganized SKUs waste time.
  -> Fix: Use WMS data to re-slot high-volume items near pack stations and streamline flow.
• Lack of inventory visibility:
  ‍If your team can’t trust the stock data, errors pile up.
  -> Fix: Integrate RFID with your WMS for real-time inventory tracking.
• Slow or manual order processing:
  ‍Disconnected systems and data entry slow everything down.
  -> Fix: Automate steps like order capture and label generation to reduce delays.
• Inflexible systems during peak demand:
  If your tools can’t scale, neither can your throughput.
  -> Fix: Use modular solutions like AutoStore’s AS/RS to flex with demand —without disruption.

Tip! Read more about RFID tags and benefits of using a WMS
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Bottlenecks don’t just delay orders — they hold your entire operation back. But with the right systems in place, every obstacle becomes a chance to move faster and smarter.

Solving bottlenecks is important but if you’re aiming for lasting, scalable improvements, you need more than quick fixes. That’s where automation steps in. Let’s explore how AS/RS systems like AutoStore boost throughput across the board.

Use AS/RS systems to improve throughput across the board

If you’re serious about boosting throughput, automation isn’t optional, it’s essential. That’s where an automated storage and retrieval system (AS/RS) like AutoStore comes in.

Instead of relying on manual picking and long travel distances, AutoStore brings products directly to the operator. It’s fast, accurate, and space-efficient.

Here’s how it boosts throughput:

• Faster picking – Robots deliver Bins right to workstations, slashing travel time
• Fewer errors – Automation reduces mistakes, increasing order accuracy
• Higher output – Streamlined workflows mean more orders processed per hour
• Smarter storage – AutoStore’s Grid uses up to 4x less space than traditional shelving

Whether you're prepping for peak season or building for long-term growth, AS/RS gives you the consistency to move faster and scale smarter.

Of course, even the most advanced automation is only as powerful as the systems it connects to. That’s why integration matters. Let’s take a look at how AutoStore connects with WMS, TMS, and ERP platforms.

How AutoStore systems integrate with WMS for smarter performance

Speed and accuracy don’t just come from automation, they come from systems that work in sync. That’s why integration is critical.

AutoStore connects seamlessly with your existing tech stack, including:

• WMSs
• Transportation management systems (TMSs)
• Enterprise resource planning (ERP) platforms

This integration ensures live data updates visibility across every stage including inventory updates, order routing, and fulfillment timing, all automatically optimized as demand shifts.

What real-time syncs looks like

When AutoStore is integrated:

• Orders are instantly routed to the right pick stations
• Inventory adjusts as Bins are picked or replenished
• Fulfillment timing adapts dynamically
• Routing decisions are based on live data

It’s warehouse agility at its best keeping your throughput high and errors low.

Built for easy integration

AutoStore is plug-and-play ready. Whether you're running a cloud-based WMS or a custom ERP, the system fits right in with no overhauls required. With expert integrators by your side, automation becomes a smooth upgrade, not a disruption.

Improving throughput is an ongoing process and not a one-time fix. Below is a quick-reference guide to help you continuously track, analyze, and optimize your warehouse throughput:

Want to see how AutoStore helps global brands increase throughput? Explore our success stories.

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Conclusion: Make throughput your advantage

Throughput isn’t just a warehouse metric, it’s the engine behind faster fulfillment, lower costs, and happier customers. By tracking the right KPIs, removing bottlenecks, and integrating smart automation, you set your operation up to scale with confidence.

AutoStore’s AS/RS system is designed to help you move faster, maximize space, and deliver with precision. Want to see what it could do for your warehouse? Get in touch! We’d be happy to show you.

FAQ

What is the throughput formula?

Throughput = Total units processed ÷ Time period

How do you measure throughput?

Track how many items or orders are completed in a set time (e.g. per hour or shift), using tools like WMS, barcode scanners, or RFID.

How to calculate net throughput?

Net Throughput = (Total units processed – Errors or delays) ÷ Time period

How do you calculate request throughput?

Request Throughput = Total order requests processed ÷ Time period

How do you calculate throughput KPI?

Measure consistent output over time (daily, weekly, per shift) and compare against benchmarks to track productivity and efficiency.

What is the difference between throughput and performance?

Throughput measures quantity—how much is processed. Performance reflects quality—how well the system operates, including speed, accuracy, and consistency