Live · as of 2026-08-23
30d $7.16M60d $17.28M90d $30.35M
Module 02 · Warehouse Surveillance

Warehouse & Distribution

Distribution-centre throughput monitored daily. Backlog, pick cycle and labor productivity are the earliest leading indicators of missed outbound cutoffs, so their drift is projected forward and converted into expedite, overtime and penalty cost.

Module question

Which distribution centres will miss outbound cutoffs, and what will the recovery cost?

Data scope

1 of 1 source tables selected — the metrics, slippages and exposure below are built only from these. Changes are PIN-protected.

Locked

Every figure on this page is traceable — module totals expand into their component slippages, and each component opens the raw source rows it was computed from.

90-day exposure
$19.81M
$4.48M inside 30 days
Open slippages
12
6 critical · 4 repeat episodes
Avoidable share
$13.80M
Exposure removable with intervention
Largest single risk
$7.53M
Order Cycle Time · Inland Empire DC

Metric surveillance

21-day rolling value versus 60-day baseline, by entity. Ranked by deviation.

Inventory Accuracy

higher is better
  • Inland Empire DC98.60%-0.5%
  • Columbus DC98.86%-0.3%
  • Newark Warehouse98.87%-0.2%
  • Atlanta DC99.05%-0.1%
  • Houston Warehouse99.09%0.0%

Order Backlog

lower is better
  • Inland Empire DC1123+74.7%
  • Columbus DC913+47.1%
  • Newark Warehouse346+35.1%
  • Atlanta DC681+14.1%
  • Houston Warehouse262+5.1%

Pick Cycle Time

lower is better
  • Inland Empire DC20.4 min+36.6%
  • Columbus DC17.9 min+21.7%
  • Newark Warehouse17.0 min+16.4%
  • Atlanta DC15.4 min+6.5%
  • Chicago DC14.5 min+1.5%

Pick Accuracy

higher is better
  • Columbus DC98.69%-0.6%
  • Inland Empire DC98.76%-0.5%
  • Newark Warehouse99.16%-0.1%
  • Atlanta DC99.25%-0.1%
  • Houston Warehouse99.19%-0.1%

Pack Cycle Time

lower is better
  • Inland Empire DC11.1 min+31.8%
  • Columbus DC9.9 min+18.1%
  • Newark Warehouse9.3 min+14.2%
  • Atlanta DC8.7 min+5.7%
  • Chicago DC8.3 min+1.4%

Order Cycle Time

lower is better
  • Inland Empire DC11.05 hrs+42.6%
  • Columbus DC9.55 hrs+25.1%
  • Atlanta DC8.10 hrs+8.1%
  • Newark Warehouse9.04 hrs+19.3%
  • Chicago DC7.63 hrs+2.4%

Units / Labor Hour

higher is better
  • Columbus DC9.2-18.0%
  • Inland Empire DC9.3-17.1%
  • Atlanta DC11.1-2.1%
  • Newark Warehouse10.9-3.9%
  • Houston Warehouse10.9-3.9%

Warehouse Overtime Share

lower is better
  • Columbus DC17.0%+137.8%
  • Inland Empire DC15.8%+124.0%
  • Atlanta DC6.9%+11.0%
  • Newark Warehouse8.4%+34.5%
  • Houston Warehouse8.6%+34.9%

Space Utilization

lower is better
  • Inland Empire DC87.7%+11.1%
  • Newark Warehouse82.7%+5.4%
  • Columbus DC82.3%+5.3%
  • Atlanta DC79.7%+1.8%
  • Houston Warehouse78.2%+0.4%

Damage Rate

lower is better
  • Inland Empire DC0.83%+86.2%
  • Columbus DC0.59%+35.3%
  • Newark Warehouse0.63%+44.8%
  • Atlanta DC0.48%+14.2%
  • Houston Warehouse0.42%+2.2%

Fulfillment Rate

higher is better
  • Inland Empire DC96.66%-1.7%
  • Columbus DC97.48%-0.9%
  • Newark Warehouse97.71%-0.7%
  • Atlanta DC98.21%-0.3%
  • Chicago DC98.45%-0.1%

Slippage board

Every detected slippage with cause, exposure ramp, owner and action.

CriticalWarehouse & DistributionRepeat episode

Order Cycle Time — Inland Empire DC

Order Cycle Time · Inland Empire DC · detected 2026-07-02 · 216 units affected

90-day exposure
$7.53M
70% preventable
Current vs baseline
11.06 hrs vs 7.75 hrs
Trend (21d vs 60d)
+42.6%
Exposure ramp
30d $1.72M · 60d $4.23M · 90d $7.53M
Why it is happening
Pick Cycle Time — Pick Cycle Time at Inland Empire DC leads this metric by 0 days (r=1.00). Cumulative pick and pack delay pushing orders past cutoff.
Downstream impact
Load readiness and departure timing at Inland Empire DC
Recommended action
Move the outbound cutoff one hour earlier and expedite only SLA-critical orders.
Accountable owner
Distribution Manager
Exposure today $1,305,830
CriticalWarehouse & Distribution

Order Cycle Time — Columbus DC

Order Cycle Time · Columbus DC · detected 2026-07-07 · 216 units affected

90-day exposure
$4.53M
70% preventable
Current vs baseline
9.55 hrs vs 7.63 hrs
Trend (21d vs 60d)
+25.1%
Exposure ramp
30d $1.01M · 60d $2.52M · 90d $4.53M
Why it is happening
Pick Cycle Time — Pick Cycle Time at Columbus DC leads this metric by 0 days (r=0.99). Cumulative pick and pack delay pushing orders past cutoff.
Downstream impact
Load readiness and departure timing at Columbus DC
Recommended action
Move the outbound cutoff one hour earlier and expedite only SLA-critical orders.
Accountable owner
Distribution Manager
Exposure today $747,129
CriticalWarehouse & Distribution

Pick Cycle Time — Inland Empire DC

Pick Cycle Time · Inland Empire DC · detected 2026-07-03 · 216 units affected

90-day exposure
$1.70M
70% preventable
Current vs baseline
20.4 min vs 14.9 min
Trend (21d vs 60d)
+36.6%
Exposure ramp
30d $385K · 60d $953K · 90d $1.70M
Why it is happening
Order Backlog — Order Backlog at Inland Empire DC leads this metric by 5 days (r=1.00). Travel distance and congestion in the pick module rising with backlog.
Downstream impact
Load readiness and departure timing at Inland Empire DC
Recommended action
Reslot the top 50 movers into forward pick and split congested aisles across waves.
Accountable owner
Warehouse Manager
Exposure today $290,820
CriticalWarehouse & DistributionRepeat episode

Order Backlog — Inland Empire DC

Order Backlog · Inland Empire DC · detected 2026-06-30 · 216 units affected

90-day exposure
$1.48M
70% preventable
Current vs baseline
1123 vs 643
Trend (21d vs 60d)
+74.7%
Exposure ramp
30d $339K · 60d $830K · 90d $1.48M
Why it is happening
Units / Labor Hour — Units / Labor Hour at Inland Empire DC leads this metric by 0 days (r=0.99). Release volume exceeding pick capacity on peak shifts.
Downstream impact
Load readiness and departure timing at Inland Empire DC
Recommended action
Add a second pick wave at 13:00 and pre-stage next-day orders during the night shift.
Accountable owner
Warehouse Manager
Exposure today $259,293
CriticalWarehouse & Distribution

Pick Cycle Time — Columbus DC

Pick Cycle Time · Columbus DC · detected 2026-07-07 · 216 units affected

90-day exposure
$1.01M
70% preventable
Current vs baseline
17.9 min vs 14.7 min
Trend (21d vs 60d)
+21.7%
Exposure ramp
30d $225K · 60d $561K · 90d $1.01M
Why it is happening
Order Backlog — Order Backlog at Columbus DC leads this metric by 5 days (r=0.99). Travel distance and congestion in the pick module rising with backlog.
Downstream impact
Load readiness and departure timing at Columbus DC
Recommended action
Reslot the top 50 movers into forward pick and split congested aisles across waves.
Accountable owner
Warehouse Manager
Exposure today $167,987
CriticalWarehouse & Distribution

Order Backlog — Columbus DC

Order Backlog · Columbus DC · detected 2026-07-01 · 216 units affected

90-day exposure
$907K
70% preventable
Current vs baseline
913 vs 621
Trend (21d vs 60d)
+47.1%
Exposure ramp
30d $207K · 60d $510K · 90d $907K
Why it is happening
Units / Labor Hour — Units / Labor Hour at Columbus DC leads this metric by 0 days (r=0.99). Release volume exceeding pick capacity on peak shifts.
Downstream impact
Load readiness and departure timing at Columbus DC
Recommended action
Add a second pick wave at 13:00 and pre-stage next-day orders during the night shift.
Accountable owner
Warehouse Manager
Exposure today $157,885
HighWarehouse & Distribution

Pack Cycle Time — Inland Empire DC

Pack Cycle Time · Inland Empire DC · detected 2026-07-03 · 216 units affected

90-day exposure
$719K
65% preventable
Current vs baseline
11.1 min vs 8.4 min
Trend (21d vs 60d)
+31.8%
Exposure ramp
30d $165K · 60d $404K · 90d $719K
Why it is happening
Pick Cycle Time — Pick Cycle Time at Inland Empire DC leads this metric by 0 days (r=0.99). Pack stations starved then flooded by uneven wave releases.
Downstream impact
Load readiness and departure timing at Inland Empire DC
Recommended action
Level wave sizes and staff two additional pack stations during the afternoon peak.
Accountable owner
Warehouse Manager
Exposure today $125,758
HighWarehouse & DistributionRepeat episode

Damage Rate — Inland Empire DC

Damage Rate · Inland Empire DC · detected 2026-07-03 · 216 units affected

90-day exposure
$658K
75% preventable
Current vs baseline
0.83% vs 0.45%
Trend (21d vs 60d)
+86.2%
Exposure ramp
30d $149K · 60d $369K · 90d $658K
Why it is happening
Average Dock Dwell — Average Dock Dwell at Inland Empire DC leads this metric by 0 days (r=0.99). Congested staging and double handling in dock aisles.
Downstream impact
Load readiness and departure timing at Inland Empire DC
Recommended action
Free two staging lanes during peak loading and retrain on stack-height limits.
Accountable owner
Warehouse Manager
Exposure today $112,746
HighWarehouse & Distribution

Pack Cycle Time — Columbus DC

Pack Cycle Time · Columbus DC · detected 2026-07-08 · 216 units affected

90-day exposure
$458K
65% preventable
Current vs baseline
9.9 min vs 8.4 min
Trend (21d vs 60d)
+18.1%
Exposure ramp
30d $99K · 60d $251K · 90d $458K
Why it is happening
Pick Cycle Time — Pick Cycle Time at Columbus DC leads this metric by 0 days (r=0.98). Pack stations starved then flooded by uneven wave releases.
Downstream impact
Load readiness and departure timing at Columbus DC
Recommended action
Level wave sizes and staff two additional pack stations during the afternoon peak.
Accountable owner
Warehouse Manager
Exposure today $70,786
HighWarehouse & Distribution

Units / Labor Hour — Columbus DC

Units / Labor Hour · Columbus DC · detected 2026-06-30 · 216 units affected

90-day exposure
$296K
60% preventable
Current vs baseline
9.2 vs 11.2
Trend (21d vs 60d)
-18.0%
Exposure ramp
30d $67K · 60d $166K · 90d $296K
Why it is happening
Warehouse Overtime Share — Warehouse Overtime Share at Columbus DC leads this metric by 3 days (r=1.00). Higher share of new and temporary labor on pick lines.
Downstream impact
Load readiness and departure timing at Columbus DC
Recommended action
Pair new hires with certified pickers for two weeks and rebalance zone assignments.
Accountable owner
Warehouse Manager
Exposure today $50,653
HighWarehouse & Distribution

Units / Labor Hour — Inland Empire DC

Units / Labor Hour · Inland Empire DC · detected 2026-06-28 · 216 units affected

90-day exposure
$294K
60% preventable
Current vs baseline
9.3 vs 11.2
Trend (21d vs 60d)
-17.1%
Exposure ramp
30d $66K · 60d $164K · 90d $294K
Why it is happening
Warehouse Overtime Share — Warehouse Overtime Share at Inland Empire DC leads this metric by 3 days (r=1.00). Higher share of new and temporary labor on pick lines.
Downstream impact
Load readiness and departure timing at Inland Empire DC
Recommended action
Pair new hires with certified pickers for two weeks and rebalance zone assignments.
Accountable owner
Warehouse Manager
Exposure today $50,129
ModerateWarehouse & DistributionRepeat episode

Damage Rate — Columbus DC

Damage Rate · Columbus DC · detected 2026-07-04 · 216 units affected

90-day exposure
$231K
75% preventable
Current vs baseline
0.59% vs 0.43%
Trend (21d vs 60d)
+35.3%
Exposure ramp
30d $55K · 60d $132K · 90d $231K
Why it is happening
Space Utilization — Space Utilization at Columbus DC leads this metric by 5 days (r=0.95). Congested staging and double handling in dock aisles.
Downstream impact
Load readiness and departure timing at Columbus DC
Recommended action
Free two staging lanes during peak loading and retrain on stack-height limits.
Accountable owner
Warehouse Manager
Exposure today $44,019

Accountability

Who owns the exposure in this module.

OwnerSlippages90-day exposureTop issue
Distribution Manager2$12.06M
CriticalOrder Cycle Time — Inland Empire DC
Warehouse Manager10$7.75M
CriticalPick Cycle Time — Inland Empire DC