Setting up a ‘Lean’ Woodworking Workshop From Scratch

This year, in the midst of Covid, and with the help of the government bounce back loan, we at Freebird Interiors finally made the move from my garage workshop to an industrial unit. We took great care to plan the space, setting up our new workshop for factory flow based on ‘Lean’ principles.

In this video I will show you a brief summary of the setting up process before taking you on a tour of the factory. Let me know what you think!

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[iangillan]

Always interesting to have a nose around a fellow woodies workshop and even after a couple of decades in the business I'm always open to new ideas and techniques. "Lean" seems to be a good way forward for us, so we'll filling bins over the holidays. All the best for the 2021...

[stevenfixo]

Really great video, thank you. The vertical storage for cutted boards, and horizontal for new boards is also a very good tip.

[darrenpaulgreen]

The shop is looking great Alastair - you and Brady have come a long way since taking it over. Thanks for th3 shout-out and all the best for 2021 and beyond!

[-_AjB_-]

I use the same twin slot racks as you. I recently added 22mm pipe insulation and they work a treat. No more scratched panels.

[ballybarn]

My job is teaching and implementing Lean in aerospace manufacturing so great you are using these techniques in your business. Keep experimenting and trying ideas you’ll make great progress

[phuongnguyen]

Looks brilliant so far. It's would be great to see this workshop running in another video. I have tried LEAN concept to furniture workshop, but that was so tough because all different components of a furniture piece are processed in different steps. That means you need more space and trolleys to store and keep the components in queue prior to moving into next steps. I see you got a lot colorful stuffs, they are probably the signals for the priority or operation order. Looks good !!! But, as you know, as market is not stable, your clients change product design time by time. I don't know how your LEAN workshop adapts that. Thank you for posting this video. People will learn a lot from that

[jacobmonti]

I would recommend getting serious about your floor tape - what colors mean what and where things go with “flow” in mind - where the workpieces go from operation to operation. Keeps the layout from getting cluttered! Include a hold area too. Awesome job so far!

[ingentingbra]

I really appriciate seeing your progress and hearing your reasoning behind.

A few lean recommendations:

1. Put som magnets on the pusher stick so you can attach it to some good place.
2. Think about the workflow and movement when using drills and impact driver. If you have to change drills/bits a lot - get more tools and mark them on the back with Pozidrive 2 for example. Consider to have a mobile cart for drills so you can keep them close to the workspace.
3. The canban cards can have a QR code with the website adress on it- so you can order even quicker.
4. Consider markings on the floor for carts so it's obvious where they shold be kept when not in use.
5. The cable to the big saw should be below the floor surface, big risk for damage to the cable now...
6. Maybe have som electricity above work surface? Cable reel automatic maybe?
7. Paper rolls should have a holder, especially in package area.
8. If you increase volume in the future - consider is you shold get some special packing for cabinet doors for example to avoid wasting time and damaging goods in transportation.

Looking forward to see what you will improve next.

Merry Christmas from Sweden

[pjlalor]

Best of luck with the new workshop, the layout looks great. thanks for sharing.

[BryanLund]

Tip for your Kanban cards and how to get them to the next level. Simple four step implementation. 1) Use the card itself as the reorder signal. Specifically meaning that you either scan or take a photo of the card and send it to the vendor. 2) You will need to discuss this "authorization" signal with your vendors before hand so that their staff accepts the email/text/fax/scan as the authorization by your company to produce or release the next order. 3) Once the scan authorization is complete, put the card in a small box where you receive materials back at the front end of your process. 4) When the items are received and put away, bring the card back to the bin.

Remember, kanban basically translates to the word, "signal". The JIT method used at Toyota to develop what was identified as "kanban" used the cards as a method of metering or controlling the flow of materials in their supply chain. The card is more than just information but a delegation of purchasing/producing authorization for you as a manager to drive control through all levels of the organization and keep costs under control and material on hand at the right times.

[philipswan]

Well done on taking the plunge and best of luck

[TheJoineryCoach]

This popped up in my feed today. Looking back it was great progress made ! It was fun and enjoyable working with you on this

[mattdunkin]

Fabulous lean shop. I used to run a plant that made custom tables, booths, and bars, and came to many of the same conclusions you ended up with. Love your comments about "experimenting", and usage of kanban for a small shop. Good luck to your business!

[joinertanner]

Great to see this come together for you I'm one step behind you in the middle of building a 4500sq ft workshop after years of dreaming months of planning hopefully few more weeks of work I should be on the home run. Have a good Christmas look forward to seeing more from you in the new year

[SamChou]

Very well thought out, lots of efficiency tips I can glean from this quick run-through, thanks for posting!

[TapioBlue]

CNC will be great, such amazing machines. If a part has to be remade one can just bring up the file and viola.
Keep on "leaning", it's the way to go.

[hughhennessy]

congratulations - onwards and upwards !

[raminybhatti]

Well done, mate. Great to see things taking off.

[pyrrhical]

Congrats. Must be a helluva feeling walking into there for you. That wadkin saw is a beast! Didn’t know they were still manufacturing. Strange to see an entire workshop/factory setup without one vise in sight. Best of luck this year

[mikes]

Wow, I’m witnessing such a transformation in your business it’s terrific. Wish you continued success 👍🏻👍🏻👍🏻