When the bin falls below 36 units, one 24-unit case is sent from reserve storage.
When this method works well—and when it does not
Works well when
- Stable movers with known case packs
- Forward faces that can hold several demand cycles
- Predictable replenishment routes
- Teams that need a simple explainable starting rule
Usually a poor fit when
- Highly intermittent demand
- Very short-lived products
- Shared faces or unidentified inventory
- Severe demand spikes not represented in the min
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.
- 1Visual low stock
- 2Operator judgment
- 3Ad hoc refill
- 1Reach min
- 2Release case quantity
- 3Confirm refill
- 4Top off before protected peak
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
Use demand during actual refill lead time
- 02
Include variability and service target
- 03
Round orders to valid case packs without exceeding usable capacity
- 04
Separate normal triggers from pre-peak top-off
- 05
Review repeat stockouts and excess touches by product
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
Increase protection, shorten lead time, or enlarge usable capacity.
Align order quantity to case pack and scheduled route logic.
Reduce allocation and return space to higher-pick frequency items.
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
Displays can surface priority, product, quantity, and destination on refill routes.
See how Voodoo worksWhen to choose something else
Static min/max labels or ordinary mobile tasks may be enough for a small, stable process.
Read how recommendations are made