Operator tool boards - Each operator has their own tool box

[pbassred]

I've worked in traditional electronics companies where each operator has their own tool box, with either good or poor tools acording to their age. I have also seen tool boards as a lean initiative. My question is how do you get from one to the other?
a) Collect up all the tool and redistribute? ( I bet they are marked up).
b) buy a completly new set?

[wmarhel]

Collect them up and redistribute the appropriate tool to the area where it will be actually be used. Chances are probably really high that you'll find that you have more of certain types of tools than you'll ever need. Be sure to throw out all the damaged tools your also likely to find.

Wayne

[pbassred]

agreed except:-
What weighs on my mind is resentment created by taking their "toys" away. Tools can be personal. Perhaps some really looked after them and took pride in them. What if the system fails and you have to give them all back?

[wmarhel]

Originally Posted by pbassred

agreed except:-
What weighs on my mind is resentment created by taking their "toys" away. Tools can be personal. Perhaps some really looked after them and took pride in them. What if the system fails and you have to give them all back?

Could you offer some additional information on the environment, generic description of the product and layout.

If the tools are supplied by the company, then they aren't personal. If the operators were required to purchase their own tools as a contingency of employment, such as some mechanics and tool & die makers, then you have to approach this in a different way.

The first step is identify exactly what tools and/or equipment are needed at each operation/process step. The operators should be, and rightly so, involved in this process.

Some people like to have "extras". I had one individual have half a dozen of the same screwdriver because "the tip might break" and wanted a spare. The problem is that there should be spares within the walls of the company (MRO program), but why did it take five spares....who knows.

Will there be some level of discomfort, probably, but once it is in place and people have an opportunity to go about their daily work without having to search for a tool that is hidden under their very nose (within their toolbox), I think they will come around. Keep in mind that certain functions such as a mechanic or maintenance person may need to maintain a toolbox which is portable.

As for failure, ask yourself what are the risks associated with moving toward tools stored on shadowboard and/or at point of use? This type of system usually only fails because supervision/management doesn't deem it important enough to follow through with it and correct the problems as they occur. As for toolboxes, don't forget to include lockers, cabinets and any drawers out in the work area as well. People can be pretty creative where maintain their "stash".

Just my 2 pence worth........

Wayne

[John Mann]

Almost certainly each girl has marked her name on her tools and you will likely get resentment if you take them away. Solder suckers in particular are often ineffective if you don't take care of your own.

Where is this UK electronics company that hasn't been moved to China?!

[Jim Wynne]

Originally Posted by pbassred

I've worked in traditional electronics companies where each operator has their own tool box, with either good or poor tools acording to their age.

According to whose age?

Originally Posted by pbassred

I have also seen tool boards as a lean initiative. My question is how do you get from one to the other?

First, the vague notion of "a lean initiative" may be misleading. If you want to do something with the tools, you should do it to solve a problem, not to achieve the appearance of lean behavior.

Once you've actually identified the problem, you should engage the workers who use the tools in finding a reasonable solution. Marching in one day and gathering up the tools is sure to be met with suspicion and resentment. Get everyone together, explain the problem, and ask them for help in solving it. You might find that there's an even better idea than hanging the tools on boards.

[pbassred]

Its actually a speculative thread. I don't work for this company yet, however I have worked in a few subcon firms. They still exist. I was thinking about the human ellement, which is a strong factor. I have "sold" this kind of change before when I got a shop floor to really use drawings and the change proceedure instead of little black books! Even when owned by the company, tools are "personal".

Jim, I meant the AGE of the tools!

Mr Mann, Any relation the Len And David? I work for them a couple of years ago. The damm company got so successful that they sold it!

[John Mann]

No relation to Len and David I'm afraid!

Worked in electronic manufacturing for 15 years with one company, since 2000 it's been a different place every year.

You are right about the human element, probably best to involve the staff as much as possible in any change. With luck you can "guide" them the direction you want to go!

John