Warehouse Workflow LabPlan a small warehouse trialPublished by Voodoo Robotics · workflows.voodoorobotics.comPerson responsible for this worksheetDateVersion01Pilot decisionWhat to do: State what the test must decide.Business questionWrite the decision the trial must answer.Example: Should Zone A use eight-order carts?HypothesisState what you expect to happen, including a number.Example: Output rises from 72 to at least 90 lines/hour while accuracy stays ≥99.8%Candidate workflowName the new method being tested in specific warehouse terms.Example: Eight-order cart picking in aisles A–DAlternative / controlName the current method used for comparison.Example: One-order-at-a-time picking with handheld scannersDecision ownerName the person responsible for this decision, task, or approval.Example: A. Rivera — Operations ManagerDecision dateEnter the exact date, due date, or review frequency.Example: July 22, 202602Boundary and sampleWhat to do: Protect the comparison.Area / locationsUse the real warehouse name or location code.Example: Zone A, locations A-01 through A-48Dates / shiftsList the calendar dates and shifts included in the trial.Example: July 20–24, 2026 · day and night shiftsOrder and SKU strataList the order-size and product groups that must be represented in the trial.Example: 1-line, 2–5-line, and 6+-line orders; fast and slow productsWorkersName the role or person and shift when it matters.Example: Day-shift picker; 6 months experienceExpected transactionsEnter a measured count and the period or group it covers.Example: 1,200 order lines during the day shiftExcluded workState exactly which work, area, shift, or cases are inside and outside the worksheet.Example: Zone A day shift; oversize orders excluded03Measures and acceptanceWhat to do: Freeze definitions before the test.Primary KPI and targetName the main success measure and the required result.Example: At least 90 completed lines/direct labor-hourAccuracy guardrailState the lowest acceptable accuracy and the exact opportunity being counted.Example: At least 99.8% correct order linesSafety / ergonomic guardrailState the safety or strain result that must not get worse.Example: No new near misses; no repeated lifts above the site limitException targetState the maximum acceptable problem rate or recovery time.Example: Fewer than 5 shortages per 1,000 lines; median recovery under 10 minutesTraining targetState what workers must demonstrate before their trial results count.Example: Complete 20 practice orders and one shortage correctly without coachingMinimum sampleEnter a measured count and the period or group it covers.Example: 1,200 order lines during the day shift04Execution and controlWhat to do: Name ownership and recovery.Pilot leadName the person responsible for this decision, task, or approval.Example: A. Rivera — Operations ManagerSystem / integration ownerName the person responsible for this decision, task, or approval.Example: A. Rivera — Operations ManagerFloor leadName the person responsible for this decision, task, or approval.Example: A. Rivera — Operations ManagerWorker briefingList what workers are told before the trial, including the goal, safety rules, problems, and backup method.Example: 10-minute huddle plus one demonstrated shortage and paper fallbackManual fallbackExplain how work continues if the new system is unavailable.Example: Numbered paper pick lists and a manual completion logStop conditionsList results or events that stop the trial immediately.Example: Any safety event or accuracy below 99.5%05Decision recordWhat to do: Capture learning, not just pass/fail.ResultSummarize the measured trial outcome against every success and guardrail target.Example: 92 lines/hour; 99.85% accuracy; no safety eventsLimitationsWrite one specific fact, concern, or item still needing proof.Example: Night-shift performance has not yet been measuredWhat went wrongList failures, delays, confusion, or workarounds observed during the trial.Example: Night shift used handwritten tote labels during two printer delaysRequired revisionDescribe the specific change needed before another test or wider rollout.Example: Add a second label printer and an approved paper-label fallbackScale / revise / stop decisionChoose the decision supported by the trial and explain any condition in the result field.Choose one…ScaleRevise and retestStopExample: Revise and retest
