Voodoo RoboticsWarehouseWorkflow Lab
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Step-by-step workflow guide

Pick many orders, then sort them

Pick items for several orders in one trip, then sort them into separate orders.

Implementation effort: Moderate · Reviewed July 2026Not sure about a term? Open the plain-English glossary
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What this fixes

Batching reduces repeated travel but creates inventory custody and later sort risk.

Works well whenMany small orders
Usually a poor fit whenVery large or irregular items
Example

The picker collects 40 products for 20 orders, then the items are sorted at a put wall.

01 · When to use it

When this method works well—and when it does not

Works well when

  • Many small orders
  • Repeated product demand within release windows
  • Manageable product size
  • Reliable order/product identity
  • Available cart or sort capacity

Usually a poor fit when

  • Very large or irregular items
  • High-priority orders that cannot wait
  • Low product overlap
  • Weak consolidation control
02 · Before and after

Show exactly what happens at each step

Write down actions that someone can see or confirm: what the worker does, what moves, who owns the next step, and what happens if something goes wrong.

Before: common problem process
  1. 1Walk each order
  2. 2Repeat locations
  3. 3Pack directly
After: better-controlled process
  1. 1Form compatible batch
  2. 2Pick common route
  3. 3Separate or sort
  4. 4Verify complete orders
03 · Basics to fix first

Get these basics right before adding technology

  • One named person owns the process, and everyone agrees what one task includes
  • Current time, accuracy, problem, and volume numbers collected using written rules
  • One named person corrects product and location information
  • A written backup method and a clear path for getting help
Fix this first

If workers cannot reliably identify the item, order, or location, correct that problem before expecting new guidance equipment to improve accuracy.

04 · How to run it

Step-by-step procedure

  1. 01

    Group orders by compatible deadline, zone, cube, and handling

  2. 02

    Cap batch size at the physical/control constraint

  3. 03

    Maintain positive batch and container identity

  4. 04

    Define short and over disposition during the batch

  5. 05

    Release completed orders without hiding wait time

Information the process must track

For each task, decide what item or order is being worked, where it comes from, where it goes, how much is expected, how the worker confirms completion, what happens when something goes wrong, and which system records the final result.

Technical notes for the warehouse software or IT team

Use one unique task ID. Re-sending the same message should not create a duplicate move or pick. Keep a way to compare records and repair differences when messages are delayed, repeated, or missed.

05 · When things go wrong

Decide what workers should do when something goes wrong

What the worker seesWhat the worker should do
Sort errors increase

Reduce batch size, add guided positions, or preserve order separation during pick.

Urgent orders wait

Reserve a priority lane outside normal batch timing.

Cart overflows

Batch on cube and handling constraints, not order count alone.

06 · Measurement

Numbers to watch

Location visits avoidedBatch formation waitSort seconds/lineOrder wait timeBatch problem rate

Before the test starts, write down what is counted, what it is divided by, when the clock starts and stops, what is excluded, and where the data comes from. Keep those rules the same through the test.

07 · Small trial

Test it on a small scale before a full rollout

Trial steps

  1. Choose one realistic area, shift, and order mix
  2. Watch the current method long enough to include normal work and a busy period
  3. Test the new method using exactly the same measurement rules
  4. Review every problem and worker workaround before expanding the change

What must be true before rollout

  • The target output is maintained for one full, realistic shift
  • Accuracy and problem recovery meet the written target
  • New workers can follow the process without unwritten tips from experienced workers
  • The backup method works, and the team can return cleanly to the normal process
Clear product disclosureWhere Voodoo may fit

Voodoo is one possible way to guide the work—not the answer to every problem.

Where it may help

Voodoo can guide batch picks and later put positions while capturing confirmations.

See how Voodoo works

When to choose something else

For tiny batches with clear scan workflows, ordinary cart labels may be sufficient.

Read how recommendations are made
08 · Calculators

Use these calculators to check the numbers

Order CSV analyzerUpload order-line data to see order size, popular products, and products often ordered together.Cart vs batch-sort vs put wallCompare multi-order carts, batch-and-sort picking, and zone picking with a put wall.Put-wall & sorting-station sizerEstimate how many order cubbies and sorting workstations are needed.