Work Flow and Productivity

rvieceli said:
[member=58857]Crazyraceguy[/member] to give you some hope  [big grin] my shop is a 20x20 garage. That’s the outside dimensions. Inside I’ve got a 16 inch Oliver jointer (1945) that’s 106 inches long, a 20 inch planer, a 20 inch bandsaw (1974), a 1969 Powermatic 66 with only 30 inches to right of the blade plus a 16 inch Electro-Mechano drill press (1963) About 24 inch deep storage along 2.5 of the walls. Also a bigger but not gigantic cyclone shoe horned between the jointer and the garage door.

The advantage of the small shop is you don’t have to take hike between machines  [tongue]

The disadvantage is that there’s not a lot of space to work on multiple projects at the same time.

I’d like about 1500-2000 square feet so I could have a dedicated welding shop but space that could be turned into a shop is not very available in our town. The city bulldozed a bunch of old railroad warehouses several years back for a highway overpass that never materialized.

I’m not sure I can get the ROI I’d need to build something.

Ron
Wow Ron  [eek] that's a lot of equipment in a small space. The biggest problem I have with space is not really the amount, it's not ideal, but I am just one guy. I'm switching from huge commercial projects, to much smaller personal furniture, cabinetry, and boxes. I really want to embrace my Shaper Origin too.
My space problem is actually shape. I have a 2-car garage, but it is far from typical. If it housed 2 cars, they would be in line with each other, rather than side-by-side. It has a total length of around 40 feet, but it's only 12' wide. That would also eliminate all of my storage options of the garage space itself.
It this point, I am partitioning it into 2 sections, limiting the shop space to 12' x 24', leaving some unheated garage behind it. There is a bit more space to be utilized between the shop and the man house, however it is an odd L shape, also only 12' wide each way. This area could be used as somewhat of a hand tools area, with a specific spot for the Origin. It currently houses my metal working tools and wood lathe, though some reorganizing may have to happen. This way I can keep the mentality of my big MFT style assembly table, and have a more traditional woodworking bench in the other room. I also have some basement space, but breaking up into all of these areas is definitely not appealing.
The MFT is still going to have to shrink from its current size though.
At this point, my plan is to put my mitersaw station (as it currently is) along one of the long walls. Then put the Festool Sysports on the opposite side. This will leave about 7 feet between them. My MFT is 4' wide, so that's a no-go. Even if I cut it down to 3', that still only gives me 2 feet on each side. I currently have 3' between the bench and the Sysport cabinets.
This is part of the mental gymnastics that I am going through. I may have to reconfigure the whole thing and incorporate the mitersaw into the Sysports? That is how I had it initially, during the rebuilding of my equipment supply after the fire, but that was when I had far fewer Systainers to store.
I have modified the mitersaw station to hold other things, drawers, etc in the mean time.
I am used to having 12' of open countertop above the Sysports now though, plus the CT on the end. That 14ish feet, plus the big black box on the end effectively uses up that 24', since there is a doorway on the side wall of one side. I can't move the mitersaw to an end wall, since they are too short.
This is still a work-in progress, I have yet to settle on a design, and I don't want to regret and redo it.
The whole thing is at least partly why I haven't just retired and left yet. While I am still there I have access to resources to get this done and my tools are not packed up and difficult to access. Plus, I have a trainee/apprentice to teach. I certainly can't wait long enough to see him through to where I am really confident in him, he is way to green and it takes years to come across all of the variants of things this job entails.
Sorry, this wasn't really supposed to be about me, it just kind of flowed into that, because this topic is top of mind.

Packard said:
Build something (anything) twice in a row.  It will teach you a lot.

Build four of something, but think of how to do it efficiently. That might mean cutting all the parts to size at one time.

It might mean making simple marking fixtures. (I do this often.  It pretty much eliminates measuring errors, or it guarantees all the items will have the same error😀.

Make simple assembly fixtures, etc.

Once I started making multiples, I gained a mindset that improved my efficiency.
Batch processing is definitely a great asset. Even with these big projects that I build, I try to get as much done at one time as possible. Sometimes it's just not practical as far as space, either for building, or for storing afterward. Just because I get it built, does not mean that the jobsite is ready to take it.
This was my point earlier about making and marking jigs, so things are repeatable.
Those angled desk units that I built for a local hospital are very repetitive, only differing slightly in a few dimensions. It would have been far more efficient to have built them all at once and I do have the physical space to do that, but...each one goes to a different floor. Those floors are being remodeled one at a time, in phases of about 6 months. It's not feasible to have one sit for 6 months after completion, and another for a year? Laminated parts (un assembled) in an unconditioned space, for that long is a recipe for disaster, and that's just from the weather factor. The potential for damage is there too.
I did another job, years ago, where there were many of the same/very similar desk units required. This was a new-build, which is why so many at once. There were 24 total. I built them over a period of a few months, mixing other things between. When the deadline push happened at the end, I built 4 of them at the same time, and this was in the old building(with far less space)
The point being both things work together, building multiples/batches, and keeping/marking jigs.
Even if you can't fully assemble the parts, if you have unique parts, that will be repeated later, cut them all at once. This is especially important in how they might fit on a sheet.

Radio, yes. I have pretty much always had one, in one form or another. Way back, before the internet made it far easier, I had a Sirius satellite radio connected to a boombox (of sorts) that I built for the space it fit into. Now a phone, Bluetooth jobsite radio and Spotify make it simple. Like [member=78000]twistsol1[/member] mentioned, I listen to stuff I have heard a million times, so there is no concentration involved. There are times when I walk back, to it playing away, and think "well that's doing nothing but wasting batteries" and laugh at myself. I could potentially be working 200 feet away from my bench.

Packard said:
At one point I was making a lot of drawers.  Setting up the dovetail jig annoyed me for some reason.  So I ended up with two identical Porter Cable jigs and two 690 routers.  I left the setup as is all the time.

All I had to do to make drawers was cut the blanks and then walk over to the jigs.

I’m not building many drawers lately and “borrowed” one of the 690s for my router table.  So, I have one jig/ router to setup.  The other is ready to go.
This is the point of my router addiction. I have 2 of the full-sized Milwaukee set-up with flush-trim and pattern bits respectively. Several laminate trimmers with specific bits or specialty bases, and 2 router tables do the same. All of them are set up to do something that I need often. Some might go days or even weeks without action, but they are instantly ready. Excessive for hobby woodworkers, for sure, but it definitely helps in a pro situation.
Only the OF1400(and one of the MFK700) are free to do odd things.

SoonerFan said:
One thing I attempted to do to improve my setup, skills, etc. was hire a more experienced woodworker like you to come to my shop and build cabinets with me.  I wanted input on my tool setup, my process, digital design, etc.  I found someone, selected the design software, and did the design.  Then I was completely ghosted.  Get returning my calls and texts.  I have no idea why,  Too bad because I was looking forward to learning a bunch from a pro.  On a positive note my skills have improved a bunch since I retired and can dedicate more time.  I am thankful for woodworking, cabinet making, etc as it gives me purpose and challenged in retirement.

Well, that's unfortunate. I wonder why he ghosted you? Maybe he felt like he under-priced what he was sharing and didn't have the guts to say it?
Anyway, "woodworking" (at least the way I see it) and "cabinetmaking" are quite different, but not mutually exclusive. One could be a legitimate woodworker, doing marquetry, jewelry boxes, turnings, trim carpentry, instrument making, etc. and never build a cabinet. On the other hand, one could build frameless cabinets, purely from sheetgoods, and never feel like that is "woodworking".
I have even been criticized, on other forums, for saying what I do with the big, laminated reception desks, is not really woodworking either. Of course, that's not all I do, but that is the mainstay of my job.
I am not much for the software side of it though. I have had some ancillary experience with it over the years, especially since the company changed brands of software about 10 years ago. There were some quirky differences that we had to work through. Software that excels in cabinet production has shortcomings in other things, curves and angles especially. In that case AutoCAD comes in, that's a completely different thing. For us, that is also 2 different people do it, and I get involved with both.

For me, retirement is an extension of all of this. I am getting into furniture making, for myself (so far anyway) My original goal is to remodel my kitchen, building it all in the garage of my house, the way it was done decades ago. Back in the day, kitchens, mantles and "built-in" shelves were built on-site. IE "built-in". With a house as old as mine, they were made from solid pine and painted. They are not individual units, installed in sections, as today. That would have been a waste of materials, in their eyes.
Sheetgoods where just not a thing yet, in the 1920s.
I'm looking forward to exploring my creativity with the Origin and possibly extending that into a stationary CNC machine too.
Wordy, sorry. It's Sunday morning and rainy. This has taken over an hour to type, while a sort-of watch TV at the same time.
 
[member=58857]Crazyraceguy[/member] When I converted the space to a shop I filled a 10 yard roll off with accumulated crap that had migrated to the garage. I also relocated all the associated outdoor gear (lawn stuff and deep storage stuff that wouldn't benefit from being in a semi-conditioned space) to a couple of sheds in the yard. If you can do that it really frees up additional space.

The sheds don't have to be fancy either, I'm using those Rubbermaid resin/plastic ones and they do a decent job.

I've never been a Systainer fan. Great if you are mobile, but I think they waste too much space if your are home based. I use drawers and a couple of cabinets.

You'll have a lot of wall space in that home shop that you probably don't have now. I've got a ton of stuff hanging on the walls. I'm actually running out of wall spaces.

I've got one of my vacs up off the floor in a dead spot on one of the roller cabinets, freed up some floor space that I don't have.  [big grin]

Ron

 
rvieceli said:
I've never been a Systainer fan. Great if you are mobile, but I think they waste too much space if your are home based. I use drawers and a couple of cabinets.

Ron

Since my work is split roughly 50/50 between shop and site - I kill two birds with one stone, Ron. Only stationary tools (bandsaw, spindle moulder, router table etc.) are in the shop, everything else gets pulled from the van as it's needed - it gets backed right up to a foot away from the shop doors. It's like having an extra room full of tools right there !! These pics are from 2018. I accidentally bought way more equipment since then, so the racking's currently just had its third redesign/rebuild.

Kevin

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When I was refacing my kitchen cabinets, I was using mitered corners with two 3/8” x 1” dowels per corner.

I made a marking gage of the dowel placement.  While I continued marking the miter corners with “A-A”, “B-B”, etc., all the miters were interchangeable.

Did this speed up marking? Yes, but to a slight degree.  Did this improve quality?  Possibly, but in an unmeasurable amount.  Did it reduce the mental pressure involved in the process? Yes.

I retained the marking gage, as this is a process I am likely to repeat.

However, I have gotten to the point where I have made so many marking gages ans assembly assists, that the take almost no time to make, and generally involve material that was destined to the trash bin, so normally I toss out these devices as soon as I am done with them.
 
woodbutcherbower said:
rvieceli said:
I've never been a Systainer fan. Great if you are mobile, but I think they waste too much space if your are home based. I use drawers and a couple of cabinets.

Ron

Since my work is split roughly 50/50 between shop and site - I kill two birds with one stone, Ron. Only stationary tools (bandsaw, spindle moulder, router table etc.) are in the shop, everything else gets pulled from the van as it's needed - it gets backed right up to a foot away from the shop doors. It's like having an extra room full of tools right there !! These pics are from 2018. I accidentally bought more way equipment since then, so the racking's currently just had its third redesign/rebuild.

Kevin

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I have the same saw horses you show.  Lately, they seem too heavy, and too slow to set up.  The resin versions have all disintegrated on me.  I am thinking of making my own light weight wood horses.

Of course I am 75, and that might be a factor in the weight.  Do you like those saw horses?  They are certainly durable.
 
[member=74278]Packard[/member] Those Toughbuilts are named 100% appropriately, Ron. Sure they're heavy, but they're seemingly indestructible. This set is nine years old now and they've been tortured on an almost daily basis for all of that time. I put a pair of 8-foot 8" x 2" sacrificial planks on them to act as a work surface for cutting most stuff, plus a sheet of 18mm (3/4") MDF on top if I need a large, flat surface to work on.
 
woodbutcherbower said:
[member=74278]Packard[/member] Those Toughbuilts are named 100% appropriately, Ron. Sure they're heavy, but they're seemingly indestructible. This set is nine years old now and they've been tortured on an almost daily basis for all of that time. I put a pair of 8-foot 8" x 2" sacrificial planks on them to act as a work surface for cutting most stuff, plus a sheet of 18mm (3/4") MDF on top if I need a large, flat surface to work on.

I cannot fault their durability either, though I have not used it as much as you have, I have given them opportunities to display any weaknesses.  None have shown up.

I have two 2” x 4” x 8’ footers that I use to connect the two saw horses.  I have two joist hangers that I drop in 2 x 4s.  I use a foam insulation panel as a sacrificial board.  That works well, except on windy days when the foam board wants to sail off to join the Americas’ Cup racers. 

I’ve had three sets of resin ones.  All of them quit on me. 

I suspect that there is a compromise that would suit me; I have not yet found it.
 
[member=75780]woodbutcherbower[/member] Two sliding miter saws in a van? There must be a reason? I assume it's because you need the capacity of the big one sometimes, but don't want to lug that monster, for the small jobs?

Systainers:
I love them. They fit my OCD perfectly, which is why I am in the hater camp with mino and coen. The change from a seemingly perfect system to whatever that mess they have now is inexcusable.
Sure there is some space wasted, but the uniformity was great. I have bought other brands of tools that use the same Systainers for that reason.
I probably could consolidate the same tools into a smaller space, but I can't believe it would make anything more efficient. I have my Systainers arranged in groups, by what they do, how often they get used, and maybe most importantly by how many small, intricate parts are involved.
Through the experience of living with them for the last 4 years (and getting a Shaper Origin) I would definitely make them 1" narrower. I did it that size initially to give me some room for some spacers to keep them from contacting the drawer guides. Now that I have the Shaper, I can make them smaller and capture the Systainers with pockets for the feet.

Saw Horses:
I know that they are not for everyone, but the ones we use in the shop are made from 3/4" plywood. They are CNC cut and nested to make good use of the sheet. We don't break them down in the shop. but the installers always keep some in the vans that way. They are light, easy to store, and incredibly strong.
4 of them, placed at the corners, can easily support and entire unit of 3/4 Melamine (40 sheets)
There are probably 50 of them around the shop, in different departments.
They are often run on the CNC machines as "demo" parts for things like "open house" vendor demos and other such events. Sometimes they are even given away to those visitors. IIRC, you get 6 per sheet, so they are incredibly cheap too, but I guess you need a machine big enough to handle a 4' x 8' sheet and that's a limiting factor  [blink]
 

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Crazyraceguy said:
Two sliding miter saws in a van? There must be a reason? I assume it's because you need the capacity of the big one sometimes, but don't want to lug that monster, for the small jobs?

Exactly this. The big fella’s a beast of a saw, but it weighs the same as a small country. The little 7.5” Mak’s perfect for trim work and can be carried in one hand. It has ridiculous crosscut capacity for its size and the dust collection is great. Beautifully engineered, too.
 
[member=17381]woodbutcher[/member] that van set up is impressive.  You can tell it is well thought out, organized, and has been refined based on your needs overtime

[member=58857]Crazyraceguy[/member] i have no idea why he ghosted me.  He made the cabinets for us once and used to own his own cabinet shop.  I felt like I sort of knew him.  I called asked him, he said yes, I asked his price, and I agreed to pay what he asked for with out any negotiation.  He told me what SW to buy for the design, I purchased it and did the design.  He came to my shop and helped refine the design.  We made the material order and then the ghosting started.  It was a bummer but I finished the project. 
 
woodbutcherbower said:
Exactly this. The big fella’s a beast of a saw, but it weighs the same as a small country. The little 7.5” Mak’s perfect for trim work and can be carried in one hand. It has ridiculous crosscut capacity for its size and the dust collection is great. Beautifully engineered, too.

I know what you mean there. The DeWalt saw I have at the shop is a 10" slider, which has sadly been discontinued, for some unknown reason. I wouldn't want to lug that thing around either. I bought it as a replacement after the fire. The one I had before was the same in every way but blade size. That first one had an 8 1/2" blade. For sheet goods and 1 x material (even 2 x construction pine) it was fine. I got it on a fantastic deal from the local Lowes store. They had it in stock forever, possibly ordered by accident? because no one would buy it. It had been marked down to less than 50% of the original price, then the tool department manager offered it to me for even less. I walked out with that thing for $150.
The odd blades would probably have been an issue for some, but having a sharpening service that supplies blades too, is quite an asset.
I don't like 12" miter saws much. They seem to have too much flex/wobble on first contact.

SoonerFan said:
[member=58857]Crazyraceguy[/member] i have no idea why he ghosted me.  It was a bummer but I finished the project. 
That's good, at least you were in deep enough to get through it.
 
In between Christmas Festivities I headed out to the shop to make shelves for the printer stand and desk units I built for our office.  I needed to flush trim the maple edge banding.  I have my MFK700 basically dedicated to this task these days as I mentioned in my original post.  Talk about productivity!  I trimmed each shelf in less than a minute. 

I did not have to switch bases or adjust the bit.  Plug in router, connect DC hose, flush trim, and put away router.  While I will likely never have the envious router setup that [member=58857]Crazyraceguy[/member] has, I can see myself leaving this router setup like this full time.  It was just so easy.  In a production shop I can easily see having a tool dedicated to a task. 

Another recent purchase (Milwaukee M12 23 Gauge Pin Nailer) was also a huge productivity gain.  No need to get out the compressor and hoses.  Just grabbed the M12 and pinned the edge banding to allow the glue to dry.  Simple as that.
 
Thanks [member=28223]SoonerFan[/member] it has been long acknowledged that I have a bit of a problem with routers.
Yes, that's exactly why I have mine set-up the way I do. I can pull one out, complete the cut, and put it away again before most guys even find the bit they need.
Almost all of my routers are dedicated to a specific task. That is why I have to carefully mark my jigs, especially if they involve a bushing. The off-set of the bit to the bushing is very important. One of my Makita compacts has a 1/4"down-spiral bit with a 3/8" bushing (to maintain minimal off-set) for a situation where I cut all the way through. At the same time, I have one of my OF1010, also with a 1/4" bit, but it's an up-cut and has a 17mm bushing. This is for a pocket cut and it gets far better dust extraction with more clearance around the bit.
 
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