Calculate the daily task capacity of a warehouse robot fleet using fleet size, cycle time, operating hours, productive utilization, and first-pass completion rate. The calculator reports accepted tasks per day, gross dispatch capacity, tasks per robot, and spare capacity against a target workload.
Accepted task capacity estimates completed work after unsuccessful first attempts are removed. It assumes cycle time and success rate stay stable as volume increases.
If failed tasks are immediately retried and included in measured cycle time, avoid subtracting the same rework twice.
With 25 robots, a 3.5-minute cycle, 16 operating hours, 80% utilization, and 96% first-pass completion, accepted capacity is about 5,266 tasks/day. Against a 5,000-task target, spare capacity is about 266 tasks.
It is the percentage of dispatched tasks completed without a retry, manual intervention, or exception workflow.
Use one method consistently. Reduce operating hours for scheduled charging or utilization for intermittent unavailable time, but do not count it twice.
Gross capacity counts dispatch opportunities; accepted capacity removes the share expected to fail on the first attempt.
Yes. A zero target shows the fleet's full estimated capacity without calculating a workload shortfall.
The formula does, but real sites may hit congestion or workstation bottlenecks that prevent linear scaling.
| Input | Unit | Role |
|---|---|---|
| Robots available | robots | User-provided planning input. |
| Average cycle time | min/task | User-provided planning input. |
| Operating hours | hours/day | User-provided planning input. |
| Productive utilization | % | User-provided planning input. |
| First-pass completion rate | % | User-provided planning input. |
| Target tasks per day | tasks | User-provided planning input. |