Layout determines steps, and steps determine speed. Goods should enter from one side and leave from the other — no backtracking, no cross-traffic.
Three common layouts
| Layout | Best for | Traits |
|---|---|---|
| U-shape | ~50–200/day, single packer, mixed goods, small space | Supplies on three sides, half-turn reach; best throughput per square metre |
| L-shape | ~100–350/day, against a wall/corner, two people | Clear packing vs staging split; easy to add a roller along the long side |
| Straight-line | ~300+/day, uniform products, multiple stations | Assembly-line style, conveyor-ready, easy to scale |
Fix the flow
- Lock a left-take/right-place or front-take/back-place motion to cut turning;
- Angle common boxes at the bench edge — never flat on the floor where people bend;
- Reserve ~1.2m of outbound staging so finished parcels don’t pile on the table;
- Place scrap and fill bins so you never turn around.
Ergonomics
- Standing bench height ~86–96cm, work surface at elbow height;
- For 8 hours standing, use a ~20mm anti-fatigue mat;
- Daily items in the ~40cm primary zone, next-daily in ~60cm;
- Overhead task lighting of 300–500 lux to cut label errors.
Speed gain
Moving a shared printer to the station can reclaim 50–100 minutes of walking per day (~200 orders × 15–30 s).
Price & estimate note
Equipment prices are indicative Australian retail bands in AUD for 2026. They vary by brand, retailer, promotion and over time, and exclude GST, freight and installation; the invoice at purchase prevails. “Seconds saved” are ranges from published warehouse-operations material — estimates, not guarantees. Time your own process with a stopwatch first. See Sources & method.
Reach-zone and 5S steps are in reach zone & 5S; sequence is in the ideal 9 steps.