Why empty travel hides in “good” pick rates

A picker can clear a solid units-per-hour target while walking further each week. That happens when slotting drifts after a seasonal push, or when new SKUs land in whatever bay is free.

Walk a sample list

Take ten representative orders and walk them with a counter or a simple map. Mark outbound metres separately from return-to-station metres. The second number is where empty travel usually lives.

Compare to last quarter’s slot map

If fast movers have crept toward the back of deep aisles, pick rates may hold for a while because experienced staff compensate — until overtime appears or new hires miss targets.

Feed the dashboard honestly

Add travel metres per line (or per order) beside pick rate on the warehouse productivity view. When the two diverge, schedule an aisle travel and slotting review rather than another motivational huddle.