Modifying Workstation Areas to Meet Customer Needs
At NPSG Australia, we understand that operational needs can shift quickly. Whether it’s a change in product type, packaging size, or fulfilment process, your workstations need to keep up. That’s why we offer tailored solutions that adapt and modify existing workstation areas, providing a cost effective and sustainable alternative to full replacements.
Photo: Modified workstation
Practical, Sustainable Modifications That Work
Rather than removing and replacing entire workstation setups, NPSG Australia focuses on practical modifications. This approach reduces waste, saves time, and minimises disruption to your operations.
We’re currently delivering a custom solution at a large warehouse in Melbourne. The facility was originally designed to process large packages. However, with a shift towards smaller parcel fulfilment, the existing workstations are being reconfigured to suit this new requirement.
Our team has worked closely with the client to design an extension shelf that attaches directly to the existing box racks. This simple yet effective modification allows team members to easily reach and pack smaller boxes, improving both efficiency and ergonomics without the need for a complete overhaul.
Once installed, the solution will give the site greater flexibility as their needs continue to evolve.
A Smarter Alternative to Full Replacement
Initially, the client’s design team had planned to order entirely new workstation setups to accommodate the new workflow. However, NPSG Australia proposed a smarter alternative to engineer modifications to the existing stations instead.
This engineered solution didn’t just solve the immediate need, it also resulted in savings of over $100,000. By modifying the current infrastructure, we delivered a better, faster, and cheaper outcome without the added burden of storing excess materials or disposing of unused equipment after the change.
The upgraded stations are designed to be reversible, so once the current fulfilment strategy changes again, the client can revert the workstations back to their original form, something that wouldn’t have been possible if they had replaced them outright. A full replacement would have led to unnecessary storage requirements and, ultimately, environmental waste.
By choosing to modify instead of replace, the client avoided adding to landfill and eliminated the need for temporary storage, significantly reducing the environmental footprint of the project.
Photo: Modified workstation
Supporting Changing Fulfilment Strategies
The Melbourne warehouse was initially set up to handle large, non-sortable items. With changes to their fulfilment strategy, it’s now being adapted to accommodate a broader mix of product sizes.
As part of this transition, NPSG Australia is also supporting the installation of a two-level pick module. This will be fitted with mail slot bin boxes to maximise storage space for smaller items and help streamline picking operations.
With the project scheduled to go live in mid-June, we’re on track to deliver a flexible solution that meets both current and future needs.
Why Modify Instead of Replace?
Adapting existing workstations brings several advantages:
Sustainability: Reduces waste and environmental impact by repurposing existing infrastructure.
Cost Savings: Avoids the significant expense of building entirely new workstations, saving over $100,000 in this case.
Faster Implementation: Gets your operations up to speed without unnecessary delays.
Flexibility: Makes it easier to adapt as your operational requirements change, and even revert when needed.
At NPSG Australia, we believe the best solutions are often the simplest. If your warehouse is evolving, we can help you get more out of what you already have.