Voodoo RoboticsWarehouseWorkflow Lab
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Problem-solving guide

We need capacity without moving buildings

Recover space and output by reducing walking, searching, queues, poor shelf use, and repeated handling before considering another building.

What to look for · What to measure · What to try this weekNot sure about a term? Open the plain-English glossary
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A simple example

A large floor area holds incomplete orders and old problem inventory. Limiting unfinished work and clearing exceptions may create usable capacity without new racks.

01 · Check the complaint

Signs to confirm on the floor

  • Space feels full even though much usable storage space is empty
  • Labor is added without proportional output
  • Queues and overflow occupy working areas
  • Peak—not average—drives the expansion argument
02 · Possible causes

Check more than one possible cause

The first explanation may sound right and still be wrong. Use the measurements in the next section to separate these possibilities.

1

Prime space allocated to slow inventory

2

Unfinished work and problems consume capacity

3

Workflow repeats travel or touches

4

Stage imbalance hides spare capacity

5

Poor face sizing creates both space and refill waste

03 · What to measure

Numbers that can change the decision

Share of usable storage space filled by storage classFor each storage type, divide occupied usable cubic space by available usable cubic space.
Space consumed by unfinished work/problem/obsolete stockMeasure positions or floor area used by unfinished work, problem inventory, and stock no longer needed.
Travel and touches/orderMeasure distance traveled and count every time a person or machine handles an order.
Capacity and workload by stageFor every step, calculate realistic output per hour and divide actual work by that capacity.
Peak duration and backlog recoveryRecord how long the peak lasts and how long it takes to clear all work that accumulated during it.
04 · Possible fixes

Choose a fix only after the facts point to it

1

Reslot and resize forward area

Use this when: Prime locations are poorly allocated

2

Reduce unfinished work through controlled release

Use this when: Queues consume floor/cell space

3

Flexible carts/walls/light guidance

Use this when: Reconfigurable execution avoids fixed buildout

05 · This week

A practical seven-day starting plan

  1. 01

    Map every square foot by productive and nonproductive state

  2. 02

    Measure cube, unfinished work, and problem age

  3. 03

    Quantify the bottleneck rather than total building fullness

  4. 04

    Test one cell or zone reconfiguration

  5. 05

    Rebuild the capacity case with measured recovery

Turn what you measured into a small test

The diagnostic compares practical options and shows which limits could change the answer.

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