Working more efficiently by collecting all the tools before the job?

[8InchCaliper]

Hi folks, I'm curious about how you manage the tools when working on a job.

I work in a small machine shop with 11 other people, it used to mainly make prototypes, but nowadays we're doing more production type jobs, and were constantly pressured by the foreman to "manage your time", I mainly work on manual mill and lathe, plus 2 Wire EDM machines, and usually I make the entire part from scratch. I noticed that I might be able to save some time by making less trips for tools. Even though I have a toolbox on wheels with many essential items, there are many other things that I would need to gather.

So I started experimenting by making a tool list just like when I went to trade school, it was ok for small jobs. However, sometimes we are required to make more complicated parts on the manual machine cos we don't have enough CNCs, I became overwhelmed very fast. To drill a simple precision hole, I would need edge finder, center drill, drill, reamer, countersink, gauge pin, cutting fluid, that's 7 items.

And this is another example, while working on a complicated part on the manual mill, I would need to gather many different fractional drills, letter drills, number drills, end mills. After collecting all that, I noticed I need all the matching collets, making more trips. After that, I found myself needing something else for setup, such as a gauge block. Then I noticed the coolant bottles were empty...and after the job, I would need isopropyl alcohol, rags, go no-go gages, sandpaper, the mating part etc etc etc, there are easily 50+ items. I'm trying to create a "master tool list" that has everything we use for reference before the job, but that seems tedious as well. Another thing I tried was breaking it down into smaller tasks, such as for when squaring the block, only collect tools for that operation.

I've been working in the shop for a few years, but I just started thinking about these things seriously like a year ago, how do you guys manage the tools? Thanks!

 

[CarbideBob]

The rule is that all tools needed should be within 1 to a max of 4 steps off the machine.
More than that is a problem and why.
Each step and each long reach is time and money lost and wasted for no reason.
As you setup and run look at the why I go for things that should be reach and grab.

 

[kpotter]

Hi folks, I'm curious about how you manage the tools when working on a job.

I work in a small machine shop with 11 other people, it used to mainly make prototypes, but nowadays we're doing more production type jobs, and were constantly pressured by the foreman to "manage your time", I mainly work on manual mill and lathe, plus 2 Wire EDM machines, and usually I make the entire part from scratch. I noticed that I might be able to save some time by making less trips for tools. Even though I have a toolbox on wheels with many essential items, there are many other things that I would need to gather.

So I started experimenting by making a tool list just like when I went to trade school, it was ok for small jobs. However, sometimes we are required to make more complicated parts on the manual machine cos we don't have enough CNCs, I became overwhelmed very fast. To drill a simple precision hole, I would need edge finder, center drill, drill, reamer, countersink, gauge pin, cutting fluid, that's 7 items.

And this is another example, while working on a complicated part on the manual mill, I would need to gather many different fractional drills, letter drills, number drills, end mills. After collecting all that, I noticed I need all the matching collets, making more trips. After that, I found myself needing something else for setup, such as a gauge block. Then I noticed the coolant bottles were empty...and after the job, I would need isopropyl alcohol, rags, go no-go gages, sandpaper, the mating part etc etc etc, there are easily 50+ items. I'm trying to create a "master tool list" that has everything we use for reference before the job, but that seems tedious as well. Another thing I tried was breaking it down into smaller tasks, such as for when squaring the block, only collect tools for that operation.

I've been working in the shop for a few years, but I just started thinking about these things seriously like a year ago, how do you guys manage the tools? Thanks!

I try to roll my tool box right next to the machine and I keep lots of tools that are used on the machines next to the machines but it's still a massive black hole I pour hours into. I am always hunting for stuff

 

[Seesecurity]

Hi folks, I'm curious about how you manage the tools when working on a job.

I work in a small machine shop with 11 other people, it used to mainly make prototypes, but nowadays we're doing more production type jobs, and were constantly pressured by the foreman to "manage your time", I mainly work on manual mill and lathe, plus 2 Wire EDM machines, and usually I make the entire part from scratch. I noticed that I might be able to save some time by making less trips for tools. Even though I have a toolbox on wheels with many essential items, there are many other things that I would need to gather.

So I started experimenting by making a tool list just like when I went to trade school, it was ok for small jobs. However, sometimes we are required to make more complicated parts on the manual machine cos we don't have enough CNCs, I became overwhelmed very fast. To drill a simple precision hole, I would need edge finder, center drill, drill, reamer, countersink, gauge pin, cutting fluid, that's 7 items.

And this is another example, while working on a complicated part on the manual mill, I would need to gather many different fractional drills, letter drills, number drills, end mills. After collecting all that, I noticed I need all the matching collets, making more trips. After that, I found myself needing something else for setup, such as a gauge block. Then I noticed the coolant bottles were empty...and after the job, I would need isopropyl alcohol, rags, go no-go gages, sandpaper, the mating part etc etc etc, there are easily 50+ items. I'm trying to create a "master tool list" that has everything we use for reference before the job, but that seems tedious as well. Another thing I tried was breaking it down into smaller tasks, such as for when squaring the block, only collect tools for that operation.

I've been working in the shop for a few years, but I just started thinking about these things seriously like a year ago, how do you guys manage the tools? Thanks!

I don't think it's really possible in a jobbing shop.
When I worked in Germany in the 80's I saw that in the production shop (I was in the toolroom) when a job was changed all the necessary equipment for that job would come on a pallet, all the tools pre-set in holders, spanners, replacement tips, gauges, measuring equipment, every single item needed to do the job. To me at the time it seemed very efficient, especially coming from a British manufacturing background. The obvious downside was the massive duplication of equipment that was required to run like that. For example if the new job had a 24mm spanner it would come on the pallet even if the current job had a 24mm spanner, same went for tooling and measuring equipment.

 

[EPAIII]

I keep the tools that are commonly/always used with a particular machine right at the machine. A rack for the mill's collets. Perfboard for wrenches, edge finders, and other tools needed for almost every job on that machine.

And I use different colors of electrical tape to color code the tools for each machine so I know where they BELONG. A larger shop could use two colors on each tool to allow for more machines.

Other tools are stored near the machines where they are used. Drill bits, commonly used milling cutters, lathe tools in QC holders, etc. This can cause some duplication, but that is more than paid for by the time saved in a commercial shop.

And each machinist should have a roll around tool chest holding a set of tools like screwdrivers, wrenches, calipers, etc. One with only the lower unit provides a work surface on the top. Or if the shop has ample benches an upper chest provides more room for tools that can be easily moved to any place where they are needed. Of course these boxes should have locks. In many shops each machinist buys their own tools. But some do provide the tools and boxes.

 

[Limy Sami]

Shall we say my shop hasn't quite grasped such a concept.

 

[jaguar36]

The vast majority of the tools I need are located within arms reach of the mill. I don't keep the metrology stuff near the mill to keep it clean,so I might make a trip to get a gauge block or whatever. Obviously if I run out of fluid or whatever I'm going to need to make a trip to get that. I don't think there is anything wrong with making a few trips while working on a job, you just ahve to avoid constantly going to get stuff, and more importantly don't waste time searching for things. I've wasted countless hours searching for stupid shit like a knife because I can't remember where I put it down or I didn't put it back where it belongs.

 

[john.k]

The army used have tools painted all sorts of gaudy colour combinations so they could go back where they belonged ....and more important see at a glance when anything was in the wrong storage.

 

[Rob F.]

I've wasted countless hours searching for stupid shit like a knife because I can't remember where I put it down or I didn't put it back where it belongs.

The worst is when you can not find it yet you specifically remember putting is somewhere where it will be safe and easy to find later...

 

[eKretz]

Yes you absolutely should have the tools gathered before the job. If your shop uses "riders" that go with the job to give a general outline of order for operations, should also have a tool list. I always gathered the necessary tools that weren't in my toolbox before starting a job. Larger places I worked that had toolrooms also had baskets that you could gather your tools from the tool room in to carry them to the machine. Standard practice. I'm sort of shocked that this is even a question.

Hunting for random tools multiple times in the middle of the job is a big time waster.

 

[Booze Daily]

Most of the stuff you're having to gather, the guys keep in their toolboxes. At least I did.
Complete drill index with letter, number, fractional.
Endmills. Commons sizes, not necessarily brand new, but not trashed.
Rags, sandpaper, scotchbrite, tapping/cutting fluid bottle.
Taps. Common sizes
Etc...

 

[sfeile]

The worst is when you can not find it yet you specifically remember putting is somewhere where it will be safe and easy to find later...

I forged and quenched some blades one time and put them in the toaster oven I was using at the time to temper them. Looked around for an hour the next day trying to find the stupid things before remembering I left them in there the night before to cool.....

 

[Limy Sami]

For all you guys that keep all their tools and gear together and ready for the job etc etc etc, .............. perhaps you could enlighten us mere mortals as to how you walk on water?

 

[DouglasJRizzo]

I've been working in the shop for a few years, but I just started thinking about these things seriously like a year ago, how do you guys manage the tools? Thanks!

I have two roller cabinets with chests and risers. When stowed, they're not more than a few steps away, and if it's a really involved setup, I just wheel them over. Makes a world of difference.

 

[guythatbrews]

The vast majority of the tools I need are located within arms reach of the mill. I don't keep the metrology stuff near the mill to keep it clean,so I might make a trip to get a gauge block or whatever. Obviously if I run out of fluid or whatever I'm going to need to make a trip to get that. I don't think there is anything wrong with making a few trips while working on a job, you just ahve to avoid constantly going to get stuff, and more importantly don't waste time searching for things. I've wasted countless hours searching for stupid shit like a knife because I can't remember where I put it down or I didn't put it back where it belongs.

Minimize your trips yes of course. Just common sense. But looking for stuff can be a bigger time waster.

Organize and put away when you are done.

 

[implmex]

Hi 8InchCaliper:
Some basic rules:
1) Don't have employees
2) Spend a ton of money to have one of everything at every possible workstation
3) Spend all your time organizing and cleaning.

If these sound like asshole comments ...well they are...kinda.
But there is some truth in them.

Some people are pigs and leave a trail of crap everywhere they go
Others are so damned anal they never get anything done.
You have to find your own personal balance.

Mine was to have most everything in my own box and to give everyone who thought the contents were fair game, a good hard Peepee slap so they wouldn't do it more than once.
I had no fucked up tools made that way by sloppy assholes littering my box, but I had no "friends" in those places either.
I'd roll my toolbox around and then set up my little kingdom and put my face down and work.
Everything was set up so I could get it and it made logical sense.
So freshly ground tap drills and perfect condition taps in the same compartment in a drawer, and a compartment for each size.
Ditto for drills and reamers.
And on and on...you get the picture.

I didn't gather what I needed for each job...it was already there in my box.
I bought gauge blocks and gauge pins and diamond wheels for the grinder and hubs to put them on and lathe tooling and collets etc etc etc.
Coworkers thought I was bonkers, but I was working contract and I could get a mold build out faster than just about anyone else and it wasn't because I was standing in a bigger pool of sweat...it was because I never had to leave the mill to get a collet or a wrench or a tap or whatever.
I had step drills I made for drilling waterlines with the pipe tap counterbores already on them, I had runner cutters already made up and subgate cutters already made up and bottle thread cutters already made up...I had to make almost none of the stuff that every body else had to spend time on.
It cost a fortune to set up that way, but it really paid off.
I don't think I ever once went looking for an Allen key...co-workers spent hours rummaging for the one that was missing from the shop set.
Fuck that! I had a few sets in my box and I'd keep them complete and in good shape always.
Nobody got to touch them but me...my Peepee slapper was always close to hand.

When I set up on my own I had to buy only the machines...everything else was already there.
I have no employees and I don't want any!

Cheers

Marcus
www.implant-mechanix.com
www.vancouverwireedm.com

 

[CAMasochism]

For all you guys that keep all their tools and gear together and ready for the job etc etc etc, .............. perhaps you could enlighten us mere mortals as to how you walk on water?

It's easy. Money! Money for a tool crib attendant. Money for double the number of tool holders. Money solves all your problems.

My shop has a standardized tool list for all of our horizontal mills and mill-turn machines so that they never have to go for tools unless it's something really different. That's around 45 tools per machine for 6 machines. Parts that need special tools get kits where the tools are kept together for them.

 

[Limy Sami]

It's easy. Money! Money for a tool crib attendant. Money for double the number of tool holders. Money solves all your problems.

My shop has a standardized tool list for all of our horizontal mills and mill-turn machines so that they never have to go for tools unless it's something really different. That's around 45 tools per machine for 6 machines. Parts that need special tools get kits where the tools are kept together for them.

That was always my problem - never enough capitol

 

[DDoug]

That was always my problem - never enough capitol

That and fact that you suffer from FSS.
.
.
.
.
.

Flat Surface Syndrome...You don't have any flat surfaces left....

 

[Nmbmxer]

The toolmaker where I first started toolbox was so big that if he had to move it far he used a forklift or flew it with the overhead. Fortunately he had his own cell with med sized lathe, knee mill, surface grinder and his box sat in the middle. He had a 3x3 box steel frame that 6 full sized Kennedy boxes were mounted. There was a central pair of fixed iron wheels with castering wheels on the ends. All the mill tools faced the mill, the lathe tools faced the lathe etc. Measuring stuff was on one end.

He had everything he needed for every job, practically ever. If he had to go to the tool crib for a special tool more than 3 times he bought it and put it on his box. If I borrowed a tool he only let me use it 3 times then he expected me (or the boss) to buy our or make our own. He had is own surface plates, gauge blocks, pin gauges, more measuring tools that you could name. Tons of little toolmakery clamps, vices, angle plates -- all made by him. He had his own Kurt vice covered in reamed/tapped holes for bolting on attachments and fixtures.

I'm sure his stuff was 2x the cost of my engineering degree. He made a lot of money because he was fast. Every tool that was listed in the first post was already on his box. He'd have a simple part made before I even got my machine setup with the tools I needed. He was an amazing mentor.

Even as an apprentice I was expected to own all my own roll around filled measuring tools, a screw machine drill index, endmills etc. I only had to go to the crib for weird stuff or to replace any cutting tool that was dull or broken. I could make most simple manual milled or turned parts without looking for stuff. I didn't have to gather tools, I just used it then wiped it off and back in the drawer it went.