Tool (storage) time

Plant improvement can be achieved by utilizing these organization techniques

by Bill Koch and Beth Sulentic

Tool storage products vary as much as the tools that are stored in the boxes. How do you pick your tool storage? First, identify your needs. The basic needs that storage products address include: storage capacity, organization, security, safety, ease of accessing tools and suitability to required movement in the shop.

In many shops, there are tool storage units for each assembly line or manufacturing cell. Many of these units are dedicated for use in a specific area with relatively limited need for movement and with a limited variety and quantity of tools. In contrast, there are general maintenance needs that require more frequent movement, and a large variety and quantity of tools. These carts have different requirements and need more strength and durability to move the added weight safely around the shop.

Regardless of whether you need a big, mobile tool cabinet or a small tool chest for specific tools in a work cell, the basics still apply. The tools must be brought close to the work, easily found, easily accessed, and safely stored and moved.

There is a general consensus that good tool organization with properly sized, quality tool storage satisfies these needs. The result is reduced search time and wasted effort. Jobs get done quicker and better with the right toolbox.

Sizing up your needs
Most shops will organize tools by type or function in separate drawers. If the application is a dedicated line situation, the drawers can be smaller and the unit’s size can also be smaller with many of these applications served by portable chests, worksite chests or tool carts located in the immediate work area. Generally, units for dedicated areas are usually up to 27 inches wide and 18 inches deep and are available in a variety of drawer configurations.

General maintenance tool cabinets or combinations will usually be larger. Most combinations are 41 inches or wider and about 18" deep, with 12 to 23 drawers to organize the tools. Since general maintenance carts must move frequently, a chief requirement is safe transportation. In this case, look for units with extra drawer retention features and sturdy 5" x 2" or larger casters for stability on uneven floors.

Everything in its place
Organizing the tools is a relatively simple procedure. Many shops use the following approach:
• Take an inventory of all the current tools in use.
• Visualize how often each type of tool is used in a typical day.
• Picture how these tools will fit into toolbox drawers while trying to gauge the proper number, size and height of drawers for the tools.

A typical shop general maintenance cart can be organized as such:

Screwdrivers and pliers: There are a wide variety of styles, shapes and sizes, but all are similar in function and low in height, so a moderately sized drawer (22" wide by 16" deep by 2" tall) might be desired. Since these items are used frequently, they are usually located waist high or slightly above for quick recognition and selection. Store locking, vise-type, long nose, angled or specialty pliers in a separate smaller drawer or in a larger drawer with snap-ring pliers and supplies.

Side cutters and wire strippers: Some shops have almost as many sizes and shapes of these as they have pliers. Similarly, 12" x 16" x 2" drawers are adequate.

Wrenches: These come in such wide varieties and different sizes that it’s difficult to determine drawer layout or drawers needed. Usually, a large drawer with room for separation is best. Sometimes, wrench organizers are needed to keep sizes separate. Because of these tools’ shape, the drawers may have to be wider or longer than normal.

Ratchet sets: Store these in drawers at a convenient access and recognition height. Many ratchet users store sockets in upright holders for quick size identification. In this case, drawers should be 4" to 6" tall. Usually, the full-width top drawer of the roller cabinet is selected as it allows the user to store several drive sizes in one convenient place.

Hammers: Store these in a taller drawer and in a lower location, since they may not be used as frequently as many other tools.

Pry bars: Store these in longer or wider drawers by themselves or in the screwdriver drawer. Drawer size should be at least 24" to 36" wide but 3" to 5" tall. A good idea for storing medium-size pry bars is to install a hanging lockable side box on the tool cart. This allows the pry bars to hang down along the box in a sleeve or tube chamber.

Punches, chisels, scrapers, files and shapers: These aren’t used as frequently and should be stored in small drawers in a less convenient location. A 12" wide by 16" deep by 2" tall drawer
is adequate for normally used items, but longer and larger tools may need storage in a bulk box or side box.

Frequently replaced machine parts or electrical components: Store these in general maintenance carts and production line boxes. Drawer sizes and configuration depend on the quantity and size of pieces and frequency of replacement.

Bulky tools and accessories: Store these in the deeper drawers near the bottom of the tool cart due to their weight and infrequent use.

Questions to ponder
When selecting the proper toolbox for your applications, it is best to take time to evaluate thoroughly what the box is expected to hold. Look at the weight per drawer, the overall tool load and the box’s ability to hold the size of tools you need to work with.

Ask yourself:
• Does the box have ball bearing drawers to make tool access easier?
• Do the drawers have a safety system latch to keep them closed while moving?
• Do the deeper or bigger drawers come double-slided to handle the expected load? Or, can an extra slide be added later?
• Is the box long enough to handle the bigger tools yet still make it down plant aisles and into service sites?
• What’s the product’s warranty?
• Can I contact the manufacturer to get replacement or repair parts?

Look for a storage manufacturer that offers a wide variety of toolbox sizes, price ranges and drawer configurations. And, get the manufacturer’s representative to help you pick the best box for your needs.

Bill Koch is the key account specialist and Beth Sulentic the marketing manager for Waterloo Industries. Visit www.waterlooindustries.com or call to learn more.

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