Warehouse Workflow Lab

Time a warehouse task

Published by Voodoo Robotics · workflows.voodoorobotics.com

Person responsible for this worksheetDateVersion

Study design

What to do: Define one observable cycle and realistic conditions.

Cycle start eventState the visible action that starts one complete repetition.Example: Pick instruction appearsCycle end eventState the visible action that ends one complete repetition.Example: Item is confirmed in the toteProduct / order stratumName the type of item or order being timed.Example: 2–5-line ambient ordersWorker experienceName the role or person and shift when it matters.Example: Day-shift picker; 6 months experienceEquipment / technologyName the cart, scanner, display, vehicle, software, or other equipment used during the timed task.Example: Eight-position cart with Acme handheld scannerPlanned sample sizeNumber of complete tasks you will time.Example: 50 complete pick cycles

Element timing

What to do: Time complete consecutive cycles.

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

Cycle IDUse one specific, observable piece of work.

Travel secondsSeconds spent moving between task locations. Do not include stationary searching or handling.

Search secondsSeconds spent looking for the correct product, location, label, tool, or instruction.

Read / scan / confirm secondsSeconds spent reading instructions, scanning, or recording completion.

Physical handling secondsSeconds spent grasping, lifting, placing, packing, or otherwise handling the item.

Waiting secondsSeconds when the worker could not continue because work, equipment, access, or information was unavailable.

Exception secondsExtra seconds spent handling a shortage, damage, unreadable label, or other defined problem.

Total secondsSeconds from the written cycle start event to the written cycle end event.

Context and motion

What to do: Use the same Cycle ID to connect this row to the timed cycle above.

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

Cycle IDUse one specific, observable piece of work.

Distance traveledRecord the route distance using one consistent unit.

Reaches / bends / liftsCount each reach, bend, or lift, or briefly describe repeated motion that may affect safety or fatigue.

TouchesCount how many times a person or machine handles the item, order, tote, or pallet.

Queue depthCount how many orders, totes, pallets, or tasks were waiting at the same time.

InterferenceDescribe another worker, cart, lift, refill task, or blockage that changed the cycle.

Worker commentRecord the worker's own explanation of what made this cycle easier, harder, or unusual.

Summary

What to do: Use typical, average, and slow-end results.

Median cycle timeUse a number and unit, and state the start and stop points when needed.Example: 42 seconds90th percentileThe slow-end time that 90% of tasks finished within.Example: 109 secondsAverageEnter the arithmetic mean time for all measured cycles, using the same unit as the other summary times.Example: 86.4 secondsException-free medianMiddle task time after removing tasks with a defined problem.Example: 74 secondsException rateUse a count divided by a clearly named opportunity and include the time period.Example: 8 per 1,000 lines = 0.8%Addressable elementPart of the task most likely to improve.Example: Searching, averaging 18 seconds per line