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Packing Station Layout Chart

Ergonomic guidance for laying out a packing station so packers reach less, bend less and handle boxes and supplies in a smooth, one-way flow.

Ref PK-0212

Draft, open for review. Check every value against the governing standard and the manufacturer’s data before use.

What it is

A packing station is where products are matched to boxes, cushioned, sealed and labeled. A good layout keeps the most-used items closest to the packer, keeps work near elbow height, and moves goods in one direction from incoming to outgoing. This lowers strain, cuts errors and speeds up packing. No single standard governs packing station design. The guidance below follows general workplace ergonomics practice.

How to use it

Watch a packer through a full order and list every item they reach for.
Rank the items by how often they are used.
Place items in the reach zones below.
Set the work surface height to suit the work and the packer.
Arrange the flow in one direction: product in, pack, seal, label, out.

Reach zones and placement

Zone	Where it is	What goes there
Primary	Within easy reach with elbows near the body	Tape dispenser, scanner, labels, the box being packed
Secondary	Reach with the arm extended, no leaning	Void fill, cushioning, common box sizes
Tertiary	Requires a step, a lean or a twist	Backstock of boxes and supplies
Overhead	Above the work surface on a rack	Rolls of film or paper, dispensers that feed down
Below	Under the work surface	Boxes in flat stock, waste bins

Key points

Light, precise work goes near elbow height. Heavier work goes a little lower so the packer can use body weight.
Height-adjustable benches let one station suit different packers.
Anti-fatigue mats and supportive footwear help with long periods of standing.
Keep box sizes in a rack sorted by size and labeled so the right box is picked first time.
Put a scale in the work surface or at the end of the line, so boxes are not lifted twice.
Use roller conveyors in and out to avoid lifting heavy boxes.
Keep a clear floor. Cords, scrap and loose fill are trip hazards.
Good lighting cuts picking and labeling errors.

Common mistakes

Putting the most-used items out of easy reach.
One fixed bench height for every packer.
Forcing packers to twist to reach boxes or tape.
Lifting full boxes off the bench and onto a scale and then a cart.
Cluttered stations where packers search for the right box.

Governing standards: No single standard governs packing station layout. Use general workplace ergonomics guidance such as NIOSH resources, and the OSHA general duty to keep the workplace free of recognized hazards.

Reference only. Verify against the current governing code or standard, the manufacturer's data and the project documents before use. Apps for Distributors disclaims liability arising from reliance on this reference.

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