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This is the final installment of five tips to help select the correct tool board.

#5 Labeling and Color-coding

This is how your tool board becomes a waste killing machine. This is probably my favorite part of making an effective and efficient tool board that associates will actually use and put tools back. As part of 5S workplace organization, the second “S” is “set-in-Order. The saying for this is “A place for everything and everything in its place!” This ensures that you have the right tool when you want it, where you want it. There is no time wasted looking for the right tool.

15-minutes_Time_Wasted_Searching_for_ToolsAccording to a recent poll, 57% of respondents stated that 15 minutes or more were lost looking for tools. Now, that’s pure waste.

Organize your tools, but take it one step further – label and color-code them. These are low cost solutions versus the waste of searching or replacing lost tools. As part of the fourth “S” in 5S, “standardize” your system. By using tool shadows and labels everyone will know where the proper tool is and more importantly where it goes. When the tool is returned to the board any one will know the correct spot to put it back. Another tip is to use Tool Tracer™ Tool Shadows with the exclusive Tool ID Band™ (patent pending). This way if you have multiple tool boards, you can color-code the board according to work area or process. So if a “blue” tool is in a “red” area it is easily seen and corrected.

Tool_Tracer_Shipping_StationDon’t forget to label your board. Make the labels a nice contrasting color like black & white, black & yellow, blue & white and so on. Also, make sure the labels and printing are large enough to see from a distance. The header for the tool board should be about 1-1//2” – 2-1/2” high. The labels for the actual tools should be a minimum of 12pt font, 18pt is better. Find what works for your area.

A well labeled board with the proper tool shadows will make your workplace more product, organized and reduce stress!

Don’t forget to check out 5S Supply for tool boards and Tool Tracer™ Tool Shadows.

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This is the fourth tip in a series of five to help select the correct tool board. Tip #4 Hooks

Believe it or not the hooks you select make a big difference. There are a variety of sizes and styles of hooks out there. Select the ones that fit your tools the best. Also consider other accessories like document holders, bins or shelves. Document holders can have work instructions, One-point Lessons, schedules and other notices. Bins and shelves can hold parts and other items. These accessories make it convenient to have these items at point of use.Tool_Board_Hooks_SS

An important feature of hooks is to make sure you get the kind that screw into or lock into the board. Some hook types just hang there. These are more problematic when come off the board asyou grab the tool. Another tip is considering having the tool horizontal (across two or more hooks) instead of just hanging up and down.

Next Tip #5 Labeling and Color-coding

This is the third tip in a series of five to help select the correct tool board.

#3 Tool Board Size

Mobile_Tool_WorksHaving the right size board at point-of-use is critical to making a tool board that employees will actually use. In Tip #1 Tool Board Type, I mentioned the types of boards (wood, plastic or steel) along with typical sizes. Wood and plastic boards are the easiest to cut to the size you need. Steel boards are usually not cut to size because of their construction. The easiest piece of advice is to not go too small or go too big. You might be tempted to go small because of cost. Consider the cost of having to get another board if you are wrong. On the other hand, many people think “I’ll get the biggest one they make” which too could be a mistake. Getting a board that is way larger than your needs and growing into it can cause undue confusion, clutter and additional waste. Stick the size you need, where you need it. Consider going mobile to make it easier to have it at point-of-use or to clean (“shine” – the third “S” in 5S) around it.

Check out one of our more popular blog post: “Finally! A Tool Shadow Board that Works

Coming up next, Tip #4 Hooks

This is the second tip in a series of five to help select the correct tool board.

#2 Location

Where you decide to put your tool board can have a big impact on whether it is used correctly or not. Consider putting it at point-of-use, as close to where the work is being performed as possible – even within arm’s reach. If the tool board is located across the room or some distance away from where the associates use it then there is a low probability that they will retrieve the correct tool needed and put it back when they are done with it.

Ergonomic_reach

Think about which tools are used most often and have those at ready access. Tools used less often can be stored in remote access. Basically, if you use it every day have it within reach. If you use it less often consider another location. Also, consider proper ergonomics. Make sure the employees do not have to reach too far or in an uncomfortable way to get the needed tool.

We will cover #3 “Size” next time.

To see Tip #1>> Select the Board Type

The Very Best of 5S Benchmarking ReportIn the upcoming posts I plan to give some concise information related to our newly published eBook “The Very Best of 5S” which is based off of our comprehensive 5S Benchmarking Survey conducted in 2011.

For a complimentary copy please click here>> “The Very Best of 5S” Benchmarking report

Let’s start off with the Executive Summary

This manuscript is an in-depth report on 5S Workplace Organization and Standardization. It sheds light on how organizations have successfully created a 5S system or the obstacles and solutions they used to overcome them. Of those surveyed, the overall rank of the effectiveness of their 5S system is a 3 on a scale of 1-5 (1=low, 5=high). This is a clear indication that there is much room for improvement. There are many suggestions and comments presented here to help coach and guide organizations as they improve their 5S systems. The level of cooperation for 5S initiatives is initially low but increases with time with the most resistance coming from the supervisor level. Contrary to this is that upper management is generally supportive of a 5S system, but the top reasons for obstacles for implementation are “lack of management support” and “not enough time.” Another finding is that the amount of training spent on 5S training is relatively low (typically two hours or less). It seems that organizations have a hard time quantifying benefits from 5S (other than 5S Audits). Companies that did calculate the financial benefits proved that the return on investment far exceeds the cost of training, supplies and manpower. The lack of reward & recognition and the ability to engrain 5S into the organization’s culture is another impediment that must be overcome. Over 50 “best practices” are shared and many suggestions on how to properly create a 5S system or improve your current one are included.

So check out the report, share it with your colleagues and friends, have discussions and give us feedback on what you see. – Tony