Voodoo RoboticsWarehouseWorkflow Lab
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Step-by-step workflow guide

Sort picked items into order cubbies

Sort picked items into cubbies—normally one cubby per order—then send complete orders to packing.

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

Put walls create a powerful holding area between two steps, but too few slots, oversized wait time, or weak completion logic can lock the entire system.

Works well whenMany small orders
Usually a poor fit whenLarge or highly variable order size
Example

A 100-item batch is sorted into 24 order cubbies. A cubby turns green when its order is complete.

01 · When to use it

When this method works well—and when it does not

Works well when

  • Many small orders
  • Batch or zone picking
  • Meaningful product overlap
  • Packing benefits from complete order presentation
  • Space for sized cubbies and operator access

Usually a poor fit when

  • Large or highly variable order size
  • Very low volume
  • Weak order identity
  • No response to missing items or blocked slots
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. 1Mixed batch arrives
  2. 2Manual sort
  3. 3Search for incomplete orders
After: better-controlled process
  1. 1Identify item
  2. 2Direct order slot
  3. 3Confirm put
  4. 4Signal completion
  5. 5Release to pack
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

    Size cubbies needed at the same time using completed output and actual wait time

  2. 02

    Fit cubby size and shape to order size distribution

  3. 03

    Identify batch, product, quantity, and destination

  4. 04

    Separate complete, incomplete, and problem states

  5. 05

    Release and reset the slot as a controlled record update

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
Wall appears full below target volume

Measure wait time by cause: missing item, packing hold, carrier hold, problem, or oversized order.

Adjacent-slot errors

Improve spacing, color, direction, scanning, or confirmation.

Packers starve while wall is full

Check completion detection and release timing.

06 · Measurement

Numbers to watch

Slot occupancySlot turns/hourSort seconds/lineItem put into the wrong order position rateIncomplete-order wait timeComplete-order release system delay

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

This is a primary Voodoo fit: wireless displays can identify and confirm dynamic order positions without wiring the wall.

See how Voodoo works

When to choose something else

If the wall is tiny, static, and low-risk, simple scan-to-label execution may be more economical.

Read how recommendations are made
08 · Calculators

Use these calculators to check the numbers

Put-wall & sorting-station sizerEstimate how many order cubbies and sorting workstations are needed.Cart vs batch-sort vs put wallCompare multi-order carts, batch-and-sort picking, and zone picking with a put wall.Capacity & bottleneck calculatorEnter the speed and staffing of each step to find which step limits total output.