To illustrate how Kaizen can be applied I will use my efforts to find better methods of storage and use of my lathe gouges. When I first purchased my Jet lathe there was little room (or money) to invest in a storage cabinet or tool roll.

When not in use my gouges were “stored” lying on my workbench. While using the lathe, I would move what I needed to lay across my table saw situated directly behind me. You can imagine, I am sure, how well this worked. Until, of course, they rolled off the saw. It never failed that the cutting edge was first to hit!

It didn’t take too long (that’s a lie) before frustration forced me to Kaizen. Looking for a low cost and simple way to protect my tools but still keep them readily available I came up with the idea of use an old kitty litter container with several lengths of PVC tube glued in.

This approach was great. It was portable, the tools were close at hand and they were all protected. Well, mostly, I did knock over the bucket once or twice but the results were much less damaging than letting the tools fall off the table saw.

Over time however I found a couple faults with this approach. The first was that sawdust and debris would collect in the bucket. The second concern happened over time as I collected more turning tools. It became increasing difficult to determine from the handle which tool was which.

Depending on each turning project, there were only a few of the tools needed. Plus I had begun to acquire a number of other lathe related tools that were not gouges and the bucket storage system was simply not appropriate.

Ultimately I determined I needed something better. A specialized cabinet ended up being the approach I took. This cabinet is made from a single piece of plywood and was constructed in one weekend. It is hung on a french cleat allowing flexibility in the shop. Over time, as you can see, I have established specialized storage locations for most of my lathe related tools.

This however was not ideal either. While I was satisfied having a special place designated for each tool or accessory, it was not conducive to efficient lathe work as I found myself going back and forth as I changed gouges during a project.

To address the need of tool storage at the lathe I developed what I call a tool saddle.

This was purposefully limited to just a few tools to force myself to keep clutter at the lathe down. On the back side I mounted an outlet strip to power various accessories I may use such as a work light or dremel. On top is a hole for my homemade depth gauge.

This approach has enabled me to protect my tools, keep my shop better organized and still provide the opportunity for efficient work.

How about you, have you developed a unique approach to maintain an organized and efficient shop? We’d love to hear about it. Share your thoughts below in the comments section or if you would like to write a guest post on this blog, drop me a line at greg_summmers {at} myturningshop {dot} com.

We waste too much of our lives doing things that are not productive or worse, just plain waste. In a few cases it gets real easy to just say no. But for most of our activities we just keep doing them the same way because that is how we have always done it. For me there is no better proof of this than my drill press example.

During my first 18 years of woodworking as a hobby my focus was on the creation. I love building. Honestly, the finishing I’d happily give away. To me it’s just not fun being that close to the finish line and yet so far away.

The worst part of woodworking (and a lathe only compounds this!) is the cleanup.

My traditional approach was to ignore this task until I was forced into dealing with it. Generally this meant when finishing! Maybe this is why I never liked finishing? It came with clean-up.

I didn’t mind walking on inches of sawdust and debris because, as I saw it, neglecting this chore meant I was able to spend time doing what I enjoyed.

Much too late, I have finally come to recognize that this lazy man approach has actually slowed me down and prevented me from having the opportunity to be as productive as possible. Losing bits and pieces in the piles of dust and debris, misplacing tools, searching for supplies; I’ve wasted weeks of my life due to disorganization and lack of cleanliness in the shop.

Things in my shop are still far from perfect, but it gets better every weekend.

One reason why things are so much better is because I’ve finally decided to outsource some of my work. Yes, I have “hired” a robot.

This robot was actually obtained with points I had on a credit card. As I saw it, it was worth the gamble of points. I wasn’t going to spend money on an unknown.

Now that I have used it for over a year, there is no doubt of its value. If my trusty DirtDog ever dies, a clone will be replacing him in short order.

Go ahead, give one a try!

Humans so often develop tunnel vision towards the world around them. Over time they neglect to see the opportunities that exist. We become de-synthesized to problems and opportunities. We begin to accept them as the norm, when to others they may not be. We are blinded to the inefficiency we create for ourselves.

Case in point, while flying home from a business trip the Delta gate agent announced a delayed departure. Not unusual for the routine traveler, but then she went on to say, “You all know how these MD-80’s are prone to these problems. I will update you on the status as soon as I can”.

For the gate agent, spending every workday at the airport handling MD-80’s, maybe this is a routine occurrence. But no matter how much I fly, these are not words I want to hear! If true, this is a big problem for Delta, but it seems their associates simply accept it as the status quo.

Imagine how much Delta has spent trying to market themselves as a safe and reliable airline. In a couple short announcements, one associtate ruined all that effort for hundreds of people within earshot, not to mention how many of those people, like myself, will pass along this story.

This made me reflect however on the things that are wrong or inefficient in my own world. And what has been the impact on my life? How many extra hours have I spend over the decades looking for a specific drill bit because I didn’t have them all organized and stored in a central location?

I use to face this when looking for a drill bit.

Today, I know where to find exactly what I need.

How often did I pull out the wrong lathe gouge?

Now there is a place for everything and everything is in its place.

I’m proud of the progress I have made, but there is so much more. The more I improve, the more I organize, the more I find to change and improve. I too have a million more steps to go, but I am glad to be on the journey.

A fellow associate once said that learning to apply lean will “ruin” you. Because the more you learn to see the waste and inefficiency in the way you and others do things the more waste you will learn to see.

Not a day goes by now that I don’t see some form a waste in my life or in companies that I do business with. We are surrounded by waste and inefficiencies.

But given the choice to be ignorant of the opportunity, and being lost in lean; I’ll take lost, but with the ability to see. While all others blindly wallow in their inefficiency, I can enjoy the great benefits to a lean journey and the improvements that are experienced in one’s life, making everything you do more organized, higher quality and faster.

Many that I ask will claim that in work and at home they often make efforts to improve. When I ask for examples of actual implemented change in the last two weeks, it’s generally quiet. At most, I might get an example of a major project underway, or one that that was already completed. Few people can name more than a handful of improvements made over the past year big or small.

Kaizen however is not about big innovative changes. It’s not about installing new systems, computers or equipment. It’s not about contracting with another vendor to handle the work you don’t like. It’s not about fundamental changes in your approach toward business.

Kaizen is about making small, incremental improvements to what you already have by means of elimination of wastes first and adding value second. Kaizen is about making dozens or hundreds of small changes over time.

Life is filled with nuisances. In work and in life, we all find reasons to complain that things take too long, move too slow, and cost too much in time, effort and energy. Kaizen is about eliminating these nuisances, all of them. And the more you look, the more you learn to see.

In the shop, it continues to amaze me how many nuisances there are. So many little inconveniences that slow you down, make your work harder than necessary, and impact the overall quality of your work.

As an example, band-saw blades have been a nuisance to me for years. When new and neatly rolled it seems easy to find a place to store a few. While I have occasionally gotten lucky trying to re-fold them once used, it’s a puzzle I’ve tired of battling. As a result I’ve hung used blades wherever I could find a spare spot. These large bands of sharpened steel inevitably get knocked off the wall.  

In less time than I have spent wrangling band-saw blades in the past, I glued up this practical while not aesthetically pleasing blade storage rack. Hung from a French cleat, I can move it as necessary around the shop. The upper portion is stationary. The vertical bar is affixed to the bottom and slides up and down in a groove of the top. All used blades can be stored in one of two sections, unfolded, while new blades hang conveniently in the center.

This is just one example of a good kaizen project, improving the current environment. It was quickly implemented for a nominal cost in time and money. I will forever on know exactly where all my blades are and none will be accidentally knocked off the wall. Nuisance eliminated!

How many more opportunities are there?

The base is still made of 3/4″ plywood and 1/4″ ply but instead of plastic sheeting for the airpillow, I used closed cell foam that I found at a local craft store.

In addition, to achieve better balance I created two airpillows on each base with the hope that they would be more balanced than having one large airpillow. It’s better…. not perfect but much better!

The foam, 3/4″ and 1/4″ plywood is all cut to 21″ X 8″. The 1/4″ ply has two 6″ diameter holes cut out. The 3/4″ ply has holes drilled for air supply. It is important the the holes be possition within the area of the matching 6″ holes on the 1/4″ ply. On these I used the plastic air fittings and 3/16 tubing found at your local hardware store.

These three pieces are sandwiched together with wood glue to bond. Take care not to glue the foam within the circular areas. Secure them all together by driving 3/4″ screws through the 1/4 ply around the perimter.

Once the glue has set set, drive a 3/4 screw and 1/5″ washer in the center of each 6″ opening securing the foam to the 3/4″ ply. About 1/4″ away from this screw you need to cut a small air hole in the foam. I sharpened the edges of a spare 3/8″ socket and puched these holes. 

Attach hoses and fittings to the top. Be sure to use a regulator to slowly increase air pressure. Too much, too fast will blow out the foam. With only 10-15 psi my Jet lathe with a 100lb. puching bag as weight can easily be slid across a smooth floor.

See it in action, below is a video of my Jet lathe being moved.  

I found more drill bits than I ever thought I had, stored in 3 different locations.
There was lots of extra sandpaper and the best of all… a new Dewalt orbital sander that I had forgotten during our move last year.

Since being indoctrinated into Lean management I have to admit (reluctantly for a natural born pack-rat) that the 5S methodology does work. At least the first four S’ are easy. The fifth, sustainment is a little more challenging to make a habit. For now I refer to an Americanized version…(It’s sad to realize that a management philosophy built on standards can have so many variations!)

In the picture below is the result of the first of 5S’ last weekend, Sorting. The pile in front is donations to local charities. The one in the back is stuff to be relocated out of my way. For the most part, yard maintenance supplies that should be in the shed with the other stuff. Fundamentally, sorting is strictly about determining what needs to be in the workspace and what does not. When in doubt, throw it out!

 
It’s outta here!

The second S and the before and after picture below is what really makes the effort worthwhile. Sweep is not really about cleaning as much as it is organizing. The object is to find a designated location for everything. Giving each item a home and using it religiously prevents the need to ever go searching again.

Before

I’ve hated looking at this mess for 18 months.
The time finally came!

After

The third of 5S’ is Scrub. Scrub is about cleaning and also about maintenance.  Making sure tools and equipment are kept clean helps ensure long life by reducing wear and tear. As an example; on bearings and bushings that may accumulate sawdust.

The forth of 5S’ is more valuable to a multi-person shop. Standardization is about setting and following rules using the first three of the 5S’. Each person works to the same standard of organization and cleanliness. This teamwork approach improves morale by ensuring each person works to support the efficiency of all.

The fifth and most difficult S is sustainment. This is where most fail. Just like a new year’s resolution, it is easy to say you’re committed but another thing to live up to it. I have found that my commitment is directly proportional to the amount of energy I invest in establishing a new habit. If I go to the effort to build a new rack specifically to store sheets of sandpaper, I am more likely to put the sandpaper there. The same applies to spices in the kitchen, toiletries in the bathroom; and office supplies at work. Try it.

 …..coming next….

….jigs-n-fixtures….

However, inspiration can also come from experiences outside of the woodworking world. Not long ago I was exposed to a company and product called Creform. Think of an erector set for a workshop, Creform’s lightweight metal pipes are intended to be cut to fit. With the addition of their specially designed connectors their product is used in factories to build workbenches and specialized carts. I’ve added Creform to my custom search if you’re interested.

For months I had been trying to find a way to improve dust collection at the lathe. I bought a heavy stand which worked OK, but it was a pain to move, on the far side for cutting out the inside of a bowl, and to the near side when shaping the outside of a bowl. 

My thought was that an articulated arm from the ceiling or wall could be much more effective and efficient. My searches for the right arm at the right price were not successful. For months I watched eBay thinking I might stumble on a dental light for a reasonable price. I searched every lamp manufacturer I could find, but had no luck finding anything strong enough.

Then, while touring a factory I saw Creform in action and the end to my search. One length of pipe and 3 joints was significantly less expensive on eBay than my original stand. It’s still doesn’t catch 100% but it is better and it is so much easier on my back. Mounted on a French cleat it can be easily relocated from one lathe to another.

Over the years, I have seen countless articles in woodworking magazines about how to make more effective use of our workspace. Efficient tool storage options, compact workbenches and effective re-use of containers accumulated all make a difference except when addressing our stationary tools.

Commercially made mobile tool bases are expensive. While I have tried versions of homemade mobile bases they are time consuming to make and the price of decent quality wheels and casters can add up. More importantly for some tools, like my jointer, these bases often do not provide the necessary footing and friction to remain motionless while in use.

To address this need I have created a base that floats on a cushion of air when it’s time to move my equipment, yet has ample surface contact to remain stationary when the tool is in use. To get an idea of how simple this is, perform a search on YouTube.com for “do it yourself hovercraft”.

For my jointer, the base is ¾” plywood cut to 19”X21” to fit the width of the base but be a little longer to facilitate air supply and balance. In this platform a 3/8” hold is drilled in one corner, 1-1/2” inches from each side for installation of an air supply nipple for connection to a regulator.

To this platform is stapled a piece of plastic sheeting. It appears plastic from heavy-duty trash bags can work but I used a heavier plastic obtained from the local U-haul store. Their plastic bags are used to store mattresses. This plastic was cut 3 inches longer and wider than the base so that it could balloon out when filled with air.  Lay the base you’ve cut on top of the plastic, wrapping the plastic up and just over the edge of the platform providing room to staple completely around the edges.To adequately seal the plastic use 3 layers of duct tape. The first layer should only have about 20% of the width over the plastic with remainder secured cleanly to the top of your platform. The next layer of tape should cover 50% of the first layer of tape and 50% of the plastic wrapping around the edge to the underside of the platform. The last layer straddles the seam of these two.

Flip the platform over and attach 1” wide strips of ¼” plywood around the edge of the platform. I screwed these in place using 5/8” wood screws left flush with the surface. This helps to secure and further seal the plastic and also provides a “foot” for the platform to sit on when the platform is not being used as a hovercraft.

Next install two screws with washers to secure the center of the plastic to the underside of the platform. This step serves to create a “pillow” or “balloon” which lifts the platform and equipment when filled with air.

Just inside of these screws you need to punch or cut a small hole as shown. This allows air to escape under the “pillow” or “balloon” providing the lift to your hoverbase allowing your tool to move on a cushion of air.

Lastly install the air nipple and connect to your air supply with a regulator. Make sure the regulator is turned off before connecting. This hoverbase requires surprisingly little air to function and will quickly burst if over-pressurized. With a little help from you to balance the tool it can be moved with ease across any smooth surface.

Certainly I will be creating more hoverbases for my shop. This entire project took less than two hours and less than $20 in materials. 

I hope you find value in this idea. If you are motivated to make one yourself, please drop me a line to let me know how it worked out! Additionally, I already know this can be improved, I hope to see modifications and improvement upon this idea from my fellow craftsman.