Warehouse work observation worksheet (Gemba)

Warehouse Workflow Lab

Warehouse work observation worksheet (Gemba)

Published by Voodoo Robotics · workflows.voodoorobotics.com

Person responsible for this worksheetDateVersion

Observation frame

What to do: Define the work and observation boundary before starting.

Process / operationName one specific task, not the whole department.Example: Pick one customer order in Zone ADate, shift, observerRecord when the observation happened, the shift, and who watched the work.Example: July 22, 2026 · day shift · A. RiveraStart eventState the visible action that marks the beginning.Example: Worker scans the empty toteEnd eventState the visible action that marks completion.Example: Completed tote reaches packingVolume and order mixDescribe how busy it was and the common order sizes.Example: 95 orders/hour; most have 1–3 productsWorkers observedName the role or person and shift when it matters.Example: Day-shift picker; 6 months experience

Transaction observations

What to do: Record consecutive work—not only memorable failures.

This section is a list.Use one row for each task, observation, test, person, field, or requirement. Add more rows when needed.

Transaction or task IDEnter the order, task, tote, or receipt identifier that connects this observation to the real work.

Start / finish timeRecord the clock time when the task began and ended.

Walking or movementRecord where the worker moved and, when possible, the distance or number of trips.

Searching / waitingRecord what the worker looked or waited for and how long it took.

Handling / confirmationRecord the physical handling and how completion was confirmed.

Exception and responseDescribe what went wrong, where it was noticed, and the practical effect.

Observed constraints

What to do: Separate facts from interpretations.

Physical constraint observedDescribe a layout, reach, space, or equipment condition that limited the work.Example: Two carts cannot pass at the entrance to aisle AInformation missing or lateState what instruction or record was unavailable and the effect on the task.Example: Pack station did not receive the carrier service until 45 seconds after scanWorker workaroundWrite down an unofficial shortcut used to keep work moving.Example: Worker writes the location on tape because the shelf label is hard to readSafety / ergonomic concernDescribe the motion, load, reach, traffic, or condition that may create risk.Example: Worker repeatedly reaches above shoulder height for a 14-pound caseQueue or blocked workDescribe work waiting or unable to move to the next step.Example: 14 totes waiting for one packing stationQuestion to validateWrite the specific question that the next observation or report must answer.Example: Do unreadable shelf labels cause most of the search time?

Immediate follow-up

What to do: Choose the next measurement rather than prescribing a solution.

Most frequent delayName the delay observed most often and show its count or time.Example: Unreadable labels caused 12 of 30 search delaysMost consequential failureDescribe what went wrong, where it was noticed, and the practical effect.Example: Wrong product scanned; tote moved to EXC-01Data needed nextName the next count, timing study, report, or observation needed to answer the question.Example: Time 30 searches in aisle A and record the reason for each delayOwner and due dateName the person responsible and the date the follow-up is due.Example: A. Rivera — July 29, 2026