Performance of bucket brigades when work is stochastic

‘Bucket brigades’ are a way of sharing work on a flow line that results in the spontaneous emergence of balance and consequent high throughput. All this happens without a work-content model or traditional assembly line balancing technology. Here we show that bucket brigades can be effective even in the presence of variability in the work content. In addition, we report confirmation at the national distribution center of a major chain retailer, which experienced a 35% increase in productivity after the workers began picking orders by bucket brigade.