Voodoo RoboticsWarehouseWorkflow Lab
Voodoo Robotics Start diagnostic
Step-by-step workflow guide

Inspect and route returned items

Inspect each return, decide what should happen to it, and keep questionable items out of good stock.

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

Returns accumulate because each unit needs a decision, not merely a location, and the problem owner is often unclear.

Works well whenEcommerce and service-parts returns
Usually a poor fit whenSimple reusable-container return
Example

An unopened item returns to stock; a damaged item goes to a marked hold area with a photo and reason.

01 · When to use it

When this method works well—and when it does not

Works well when

  • Ecommerce and service-parts returns
  • Multiple disposition outcomes
  • Condition or serial verification
  • Meaningful recovered-value opportunity

Usually a poor fit when

  • Simple reusable-container return
  • Regulated or hazardous returns requiring specialized compliance
  • Very low-value goods better handled by a fixed policy
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. 1Open box
  2. 2Decide from memory
  3. 3Create pile
  4. 4Research later
After: better-controlled process
  1. 1Identify return
  2. 2Inspect by rule
  3. 3Choose disposition
  4. 4Route physically
  5. 5Close financially
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

    Identify order, item, reason, and ownership

  2. 02

    Use a finite decision tree for condition and disposition

  3. 03

    Physically separate sellable, repair, vendor, scrap, and investigation

  4. 04

    Require evidence for overrides

  5. 05

    Age unresolved work by reason and value

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
Investigation pile grows

Set value-based service levels and authority limits.

Sellable returns remain unavailable

Separate reinventory capacity from complex problems.

Condition grading varies by worker

Use visual standards, sample calibration, and check.

06 · Measurement

Numbers to watch

Return cycle timeRecovery valueDisposition accuracyUnresolved ageSellable reinventory timeTouches/return

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

Wireless displays can identify dynamic triage and disposition locations and present task-specific instructions.

See how Voodoo works

When to choose something else

The difficult part is policy and evidence; lights cannot decide product condition or financial ownership.

Read how recommendations are made
08 · Calculators

Use these calculators to check the numbers

Capacity & bottleneck calculatorEnter the speed and staffing of each step to find which step limits total output.Warehouse mistake-cost calculatorEstimate what warehouse mistakes cost each year, including those caught before and after shipment.