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WAREHOUSE-OPERATIONS5 MIN READ

Walk the Bottleneck Before Adding Labor

Apply Theory of Constraints to improve outbound flow by protecting the true constraint.

Late outbound Orders are behind, packing benches are uneven, and everyone has a theory. You need to protect shipped throughput before adding cost. The wrong fix pushes more work into the queue that is already limiting the system. TOC Identify → Exploit → Subordinate → Elevate → Repeat The constraint is the point that governs total output. Improve it first; synchronize the rest of the warehouse to keep it fed but not flooded. Reflex Add labor everywhere Capacity decisions become focused instead of emotional. A non-constraint improvement only helps if it improves the constraint’s flow. 01 Find 02 Protect 03…

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