A ten-part service kit cannot close until all ten correct part versions are scanned into the kit tote.
When this method works well—and when it does not
Works well when
- High-mix component sets
- Sequence- or revision-sensitive work
- Repeatable kit families
- Operations where training and verification matter
Usually a poor fit when
- Single-component work with obvious identity
- Complex assembly requiring engineering work instructions beyond location guidance
- No reliable bill of materials or revision control
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.
- 1Print bill of materials
- 2Search bins
- 3Check mentally
- 4Send kit
- 1Identify kit
- 2Guide components
- 3Confirm quantity
- 4Resolve shortage
- 5Close complete kit
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
Freeze the applicable bill of materials/revision
- 02
Present one kit or controlled batch
- 03
Guide and confirm each required component
- 04
Handle shortages without falsely closing the kit
- 05
Record completion and ownership of correction work
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
Make revision/lot eligibility part of source selection and confirmation.
Create partial-kit status and explicit shortage recovery.
Change confirmation placement, check sequence, and use item verification where needed.
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
Kitting and sequencing are strong Voodoo fits for visible step guidance, quantities, icons, arrows, and acknowledgements.
See how Voodoo worksWhen to choose something else
Displays should not replace controlled bill of materials/revision logic or detailed safety-critical assembly instructions.
Read how recommendations are made