Every high-growth ecommerce business needs to ensure they optimize their order fulfillment process to keep customers satisfied and scale their brand.
There are many steps within the order fulfillment process that can be tracked for improvement. Packing stations are often overlooked but they are a crucial part of fulfillment. Setting up a pack station for maximum efficiency is a big part of warehouse optimization and ecommerce success. If your packing stations can’t move orders through the line quickly and accurately, your brand will suffer.
Here are some basic ways to make sure your fulfillment packing station works well to keep operations smooth, minimize errors, and maximize productivity.
What is a Fulfillment Packing Station?
If you’ve heard of pick and pack, then you probably know what a packing station is. It’s where ecommerce products are picked from a shelf and put (packed) into the box to be shipped to a customer.
A packing station is the hub of many important variables of your ecommerce fulfillment flow. This is where the product is picked, packaging selection takes place, any inserts or kitting are added, and branded tape or labels are added to seal the box.
It’s also an important step in your quality control system. Every detail about how an order should be packaged, including any special instructions, will be communicated to the pack station packer through an integrated warehouse management system (WMS).
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Warehouse Packing Station Layout for Maximum Efficiency
The goal of any packing station is to get customer orders assembled to ship out. The packing process workflow should be streamlined to allow workers easy access to the products, packing supplies, and everything they need to do their job quickly and easily with the least amount of strenuous effort.
What this means is arranging each work area or packing table to allow the worker to follow a logical order from picking to packing to shipping, reducing unnecessary movement. The use of automation, robotics, or conveyor belts can help move items between different stages of the packing process more efficiently than doing so manually.
1. Ergonomic Design
Adjustable Workstations: Allow workers to adjust the height and layout of their packing table to reduce fatigue and prevent injuries.
Comfortable Seating and Anti-Fatigue Mats: Provide ergonomic chairs and mats to improve comfort for workers who stand for long periods.
2. Organized Storage Solutions
Shelving and Bins: Keep packing materials like boxes, bubble wrap, and tape organized and within easy reach. Some warehouses use modular systems to change the setup for different needs.
Labeling Systems: Clearly label all storage areas to quickly locate necessary items.
3. Packing Materials and Packaging Station
Variety of Packaging Options: Ensure availability of various box sizes, padded envelopes, and other packaging materials to accommodate different products.
Sustainable Materials: Use eco-friendly packing materials to appeal to environmentally conscious customers.
4. Apply Technology to Support the Flow
Barcode Scanners: Implement barcode scanning to reduce errors and speed up the packing process.
Automated Packing Machines: Use machines for repetitive tasks like box sealing or label printing.
Inventory Management Software: Integrate with warehouse management systems to track inventory levels and packing status in real-time.
5. Safety Equipment
Protective Gear: Provide gloves, safety glasses, and other protective equipment to prevent injuries.
First Aid Kits: Keep first aid supplies readily available in case of accidents.
6. Environmental Controls
Climate Control: Ensure the packing station is kept at a comfortable temperature to maintain worker productivity.
Lighting: Provide adequate lighting to reduce eye strain and improve accuracy.
7. Backup Systems
Redundant Equipment: Keep backup equipment like label printers and scanners to minimize downtime in case of failure.
Disaster Recovery Plans: Have plans in place to quickly recover from unexpected disruptions.
Improving the Warehouse Workflow
If you see fulfillment processing times slowing down in your warehouse, it’s time to review the packing area and packing process for improvement. There are many aspects of your overall procedures that may need attention.
- Training and Supervision – regularly train workers on best practices and safety protocols. Establish company-wide performance metrics to check and provide guidance as needed.
- Quality Control Measures – in some warehouses a verification station may be a necessary step alongside your packing stations. Have a dedicated workbench where packed orders can be double-checked for accuracy before shipping. Standard operating procedures and checklists ensure consistency and reduce errors.
- Implement Visual Guides and Communication Tools – keeping your workers informed on a real-time basis is so important. Use intercom systems to allow for easy communication between different areas of the fulfillment center. Display digital dashboards so everyone knows the key performance indicators (KPIs) and real-time updates of the warehouse.
Bottom Line
Despite what it may seem, packing stations aren’t static, they should be looked at for continuous improvements and updates.
Make sure your entire team is aware of a robust feedback system, to encourage employees to surface things that may need adjustments. Perform regular audits to assess efficiency and identify bottlenecks.
This post was written by Maureen Walsh, Marketing Manager at DCL Logistics. A writer and blogging specialist for over 15 years, she helps create quality resources for ecommerce brands looking to optimize their business.
Tags: warehouse management
