Throughput
Also: Durchsatz, Durchsatzleistung, Systemdurchsatz, Förderdurchsatz, picks per hour, PPH
AI-generated
Throughput refers to the throughput rate of a warehouse or conveyor system and indicates how many units – such as picks, packages, or pallets – can be processed per unit of time. It is the key performance indicator for evaluating the efficiency of intralogistics systems and processes.
Key facts
- Throughput indicates how many units a system processes per unit of time and is the central performance metric in intralogistics.
- For reliable planning, a distinction must be made between gross and net throughput, as well as between average and peak load values.
- Bottlenecks within a system always limit the overall throughput of the entire facility.
- Vendor-specific throughput figures are often based on ideal conditions and should be validated using a defined product mix.
What is Throughput?
Throughput describes the quantity of units that a system, facility, or process handles within a defined period of time. In intralogistics, this metric is typically expressed in picks per hour, packages per hour, or pallet movements per shift. It is considered the single most important indicator of the performance of picking systems, conveyor systems, sorters, and automated warehouses. Without a clearly defined throughput figure, neither capacities can be planned nor investment projects evaluated on a sound economic basis.
How is it measured in practice?
Throughput is generally read from system logs of the Warehouse Management System (WMS) or the control software (PLC/WCS). It is important to distinguish between gross throughput and net throughput: gross throughput counts all processed units including failed attempts and rework, while net throughput only accounts for successfully completed operations. In practice, throughput fluctuates considerably – depending on order structure, product mix, shift utilization, and seasonal peaks. Reliable planning therefore relies not solely on the peak value, but also examines the average and standard deviation over a representative period.
Bottlenecks can be identified through a bottleneck analysis: any station operating more slowly than the processes upstream and downstream of it limits the overall throughput of the system. This principle corresponds to the Theory of Constraints (ToC), which is widely used in logistics planning, though not all vendors interpret it in the same way.
What matters when selecting and designing a system?
When designing a system, you should pay particular attention to the following aspects:
- Peak load capability: Maximum throughput must be designed for realistic peak loads – not just the daily average.
- Measurability: Only what is properly captured can be managed. Clarify early on which data points the system provides and at what level of granularity.
- Comparability: Vendor-specific throughput figures often refer to ideal conditions. Insist on a defined product mix and a realistic error rate for benchmarking.
- Scalability: Check whether throughput can be expanded modularly without having to restructure the entire system.
There is a close relationship between throughput and order cycle time: high throughput alone does not guarantee short cycle times if buffers and sequencing are not optimally designed. Both metrics complement each other and should be considered together.
Related terms
- Auftragsdurchlaufzeit
Order throughput time refers to the total time from the receipt of an order to its dispatch to the recipient. It encompasses all waiting, processing, and internal transport steps, and serves as a key indicator of the performance of a warehouse or fulfillment process.
- Batch-Kommissionierung
Batch picking is a method in which multiple customer orders are consolidated into a single pick run. This allows the picker to travel one route while simultaneously covering positions from different orders.
- Bestandscontrolling
Inventory controlling refers to the systematic monitoring, analysis, and management of stock levels using defined key performance indicators. It connects logistics and procurement to reduce tied-up capital and ensure delivery capability.
- Bottleneck Analyse
Bottleneck analysis identifies the process step with the lowest capacity in a logistics system, making the limiting factor for overall throughput visible.
- Dimensionierung
Dimensioning refers to the systematic design of warehouse capacities, material handling equipment, and logistics systems based on volume frameworks, throughput requirements, and peak loads. It forms the planning foundation for investment decisions in intralogistics.
- Disposition
Disposition refers to the operational planning and control of resources, quantities, and orders in logistics – for example in transport or materials disposition. It encompasses capacity assignment, scheduling, prioritization, and response to disruptions.