The next released group of orders needs 110 units but the pick shelf holds 70, so a 48-unit refill is sent first.
When this method works well—and when it does not
Works well when
- Wave or planned order release
- Reliable allocation and reserve inventory
- Tight faces with known outbound demand
- Operations able to sequence refills before picks
Usually a poor fit when
- Completely waveless unpredictable release
- Unreliable inventory records
- No safe timing separation between forklifts and pickers
- Demand allocations that change after release
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.
- 1Release wave
- 2Faces deplete
- 3Emergency refill
- 4Wave stalls
- 1Analyze wave
- 2Create refill set
- 3Complete critical refills
- 4Release protected picks
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
If workers cannot reliably identify the item, order, or location, correct that problem before expecting new guidance equipment to improve accuracy.
Step-by-step procedure
- 01
Calculate face shortage against allocated demand
- 02
Prioritize by earliest pick need and consequence
- 03
Release only feasible reserve tasks
- 04
Confirm critical refills before dependent work
- 05
Recalculate when orders or inventory change
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.
Decide what workers should do when something goes wrong
Move critical-refill cutoff earlier and analyze reserve task capacity.
Set cancellation handling and prevent excess face load.
Model equipment, lot, hold, and retrieval constraints before release.
Numbers to watch
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.
Test it on a small scale before a full rollout
Trial steps
- Choose one realistic area, shift, and order mix
- Watch the current method long enough to include normal work and a busy period
- Test the new method using exactly the same measurement rules
- 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
Voodoo is one possible way to guide the work—not the answer to every problem.
Where it may help
Light-directed destinations can make a fast pre-wave refill route easier to execute and confirm.
See how Voodoo worksWhen to choose something else
The allocation and dependency logic must remain in the warehouse management system (WMS) or software that assigns and coordinates work.
Read how recommendations are made