How to optimise material flow at the workstation?
Ergonomic layout follows the motion sequence. The workpiece flow ideally runs left to right or front to back so no counterflow occurs. Working height is chosen by task: higher for precision work, lower for force-intensive tasks.
View workplace equipmentHow do you define reach zones correctly?
The reach zone is the area the hands cover without twisting the upper body. EN ISO 14738 distinguishes three zones: the near zone for constantly used parts, the extended zone for frequently needed material, and the outer reach zone for rarely used items.
The optimal reach zone lies roughly 25 to 35 cm in front of the body. Anything placed here is accessible without stretching and protects the shoulders and back. Tools and bins that are handled continuously always belong in this inner zone.
How do you supply material the lean way?
Lean principles aim to eliminate waste. At the workstation this means supplying material exactly where it is needed, in the right quantity and facing the grab direction. Kanban bins and flow racks ensure that full containers slide into place automatically.
- 5S: sort, set in order, shine, standardise, sustain.
- First-in-first-out via flow racks and inclined shelves.
- Kanban cards or a two-bin system for replenishment.
- Small load carriers in a uniform size for stable grab paths.
- Turn material into the grab direction with the label facing the operator.
How do you arrange the workstation ergonomically?
Ergonomic layout follows the motion sequence. The workpiece flow ideally runs left to right or front to back so no counterflow occurs. Working height is chosen by task: higher for precision work, lower for force-intensive tasks.
- Very frequent grabs in the near zone, rare ones further out.
- Height-adjustable benches enable sit-stand alternation.
- Tiltable bins ease removal and reduce wrist strain.
Frequently asked questions
What is the optimal reach zone at a workstation?
Roughly 25 to 35 cm in front of the body at elbow height. In this near zone parts are reachable without stretching or twisting, which protects the shoulders and back.
What does the two-bin system achieve?
It is the simplest kanban entry point. An empty bin becomes the reorder signal while the second one secures supply. This avoids gaps and overstock at the workplace.
Which standard describes reach zones and working heights?
EN ISO 14738 defines body dimensions and reaches for the design of machine workstations and serves as the basis for ergonomic layout.
How do you cut search times at the workstation?
Through 5S and fixed, labelled storage locations. Every part has a defined place in the grab direction, so searching and walking are eliminated.
Looking for a workstation with optimal material flow?
We supply height-adjustable benches, flow racks, open-front bins and kanban systems for short paths and ergonomic working.
Ergonomically planned
Reach zones and heights per EN ISO 14738.
Lean supplied
Kanban and flow racks for short paths.
Less waste
5S ensures fixed places and order.
Expert advice
Specialists help plan your workstation.