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Organization on the Machine Shop Floor

The organization is the cornerstone of efficiency and profit in a machine shop. We have focused on people, processes, machines, and tools in previous blogs. The focus today is an organization on the machine shop floor. One of the fundamental parts of the organization is flow. Adding new equipment, or even starting a new business, the layout of tools, machines, and grouping may not be things you have considered.

 

1.Streamline the journey — The little inefficiencies over time are what accumulate to create the bigger problems. You might think it goes without saying, but in many facilities, a piece must crisscross the floor numerous times as it’s transformed from the raw stock into a finished product. In practice, a straight-line approach (or at least a direct path) is a much more efficient method of CNC machine layout.

Consider the complete process from receiving and storing raw materials to each stage of processing, any stock that has to be inventoried, and final shipment. The time it takes to implement a CNC machine shop layout that naturally flows through each stage of the production process will be more than made up by the time you save, reducing the amount of ground that both materials and personnel must cover.

 

2.Group processes sensibly — Just as important as considering the flow of physical flow of production it is also important to consider grouping similar operations physically close together. One of the best examples of this is keeping your QC equipment close to your fulfillment area so that nothing gets overlooked and pieces can move directly from inspection to storage or fulfillment.

This grouping philosophy extends to planning production to run similar operations together to reduce changeover. This process of cellular manufacturing, where a part may not experience production from start to finish, or an order with a variety of parts may not be run in succession, may seem in opposition to the streamlined process, but simply follows that same principle of flow expanding it to scheduling. Similar parts utilizing the same tool or rough stock, for example, may be run in sequence and temporarily stored.

 

3.Allow easy access to assembly — Depending on the scale and format of your facility, pieces may be arriving in the assembly area from different machines at different times. Keeping your assembly equipment centrally located and easily accessible creates a production flow with a focus on efficiency.

This can mean relocation of production equipment or assembly equipment with the introduction of a new machine. Don’t overlook this added time and cost when installing new machines as it will be paid for through efficiency every day ahead from there.

 

4.Keep tools organized — Beyond the CNC machine layout, other organizational components of your facility, such as tool access and storage, can have an impact on your efficiency and productivity. A key consideration is making sure that tools, collets, clamps, and other equipment are kept where they are supposed to be so they can be easily located when needed. This can be accomplished with rolling storage cabinets, labelling, and even foam inserts for each tool.

Generous storage space is needed for easy access and visibility. Searching for a lost tool over and over due to a messy tool storage area will frustrate the employee and continually affect productivity. Keep in mind some tools that are used repetitively may need to stay at a workstation to enhance productivity. Others should be returned after each use.

 

5.Keep only what you need — Tool organization can directly affect workspace. Keep tools that aren’t needed at a workstation adds to both physical and mental clutter. Beyond the workplace, it is particularly ineffective to keep tools that are no longer needed.

On a larger scale, if you no longer use or need a piece of equipment, it’s not only negatively affecting your machine shop floor plan layout, it’s likely impeding your processes. Selling unneeded machinery is an easy way to recoup costs and add to the ROI of your equipment.

 

Observing personnel at work helps assess organization on the machine shop floor. Consider wasted time in transportation, accessing or finding tools, and moving things to temporary locations. A workstation that is too small for assembly or setup will see time wasted when needed tools or parts must be continually moved. An area too large leaves room for clutter. Being observant of the amount of time an employee leaves their station to access tools and other equipment indicates potential for improved storage for workflow. This relates directly to eliminating unnecessary processes as detailed by lean manufacturing principles.