Try the same with a glass of water.
You either check capacity and have a hard stop on the real capacity,
or you maintain your capacity with a value that corresponds to a 150%
or you just don't do any capacity check.
A consultant should consult, and this does not mean he is a fairy who fulfills any wish.
A consultant is an expert who knows the constraints of the system, can explain the pitfalls and disadvantages to the client
So it is actually your turn if you make overutilization a strategy, which means you maintain a higher capacity as I already proposed, and make the aisles a bin too as you just said or you eventually take the challenge and look for the root cause that makes over-utilization necessary.
Why did you make the capacity per bin so small as they are if they can accommodate 50% more.
Is the warehouse too small in general or do you only talk about peaks? is the planning inaccurate? Do you have to many slow movers and dead stock?
While calculating the capacity of the warehouse, we came across two different capacities. Theoretical Capacity and Operational Capacity. which of the two should be maintained in the system in the bin capacity?
the Theoretical capacity includes the isles and the dead space that cannot be utilized due to safely reasons and material stacking limitations. however, the operational capacity can be overrun and should be captured in the system. These over utilization should be captured in the system and the utilization should show that the space is over occupied.
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