Five Warehouse Planning Exercises

WarehouseOps · Version 2.0 · 20 September 2026

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Invented cases for discussion. Free for internal classroom use when WarehouseOps is credited and the original file is not resold.

1 · Fill rate

100 lines ordered, 90 fully shipped; 1,000 units ordered, 980 shipped. Calculate both measures.

Answer and discussion

Line fill 90%; unit fill 98%. The larger percentage does not mean every order is complete.

2 · OTIF

100 orders: 80 on time, 90 in full, overlap unknown. What can you report?

Answer and discussion

A feasible range of 70–80%. Ask for measured overlap before publishing one OTIF percentage.

3 · Feasible EOQ

EOQ is 20; MOQ 25; pack 12. What is the smallest feasible order?

Answer and discussion

36 units. MOQ alone is not a valid pack multiple.

4 · ABC

Two SKUs have values 9,900 and 100. Apply the documented boundary convention.

Answer and discussion

First SKU A, second C. Explain why there is no B SKU in this small dataset.

5 · Action review

A KPI is below target. Write a better action than “improve performance”.

Answer and discussion

Specify the observed gap, investigation, owner, due date and evidence; distinguish action completion from outcome improvement.

Use and adaptation

Free for internal classroom use with attribution. No resale or redistribution. Adapt and approve at your site. Examples do not constitute professional certification. Support: support@warehouseops.in.