In September 2021, we were approached by a manufacturer building a new factory to assist in developing their engineering team. Essentially, we started with a blank slate.
This was a vast space—600,000 sq. feet of factory floor, including a well-sized engineering workshop.
Certain decisions had already been made, but the majority of the engineering workshop was yet to be designed. The Reliability Manager at the time invited us to contribute, aiming to create a highly efficient workshop by incorporating best practices from our extensive experience.
This was an exciting challenge, as many common frustrations are associated with poorly designed engineering workshops, including:
Common Engineering Workshop Issues:
- Poor Layout: Inefficient workshop design often leads to duplication of work and wasted time, such as having to walk across the workshop to find tools.
- Distant Engineering Stores: If spare parts storage is too far from the workshop, engineers waste time walking back and forth. Often, once they return to the workshop, they realise they need another part, leading to further inefficiencies.
- Limited Workspace: Workshops are sometimes treated as an afterthought, squeezed into leftover spaces, leading to poor workflow and a lack of room to work on essential equipment.
Addressing These Challenges
For this particular factory, the workshop was centrally located to the initial production lines. However, given that the factory was the size of 18 football pitches, excessive walking remained a concern.
1. Mobility Solution: The Golf Buggy
Any time an engineer spends walking is non-value-added time. Engineers should be focused on asset maintenance and continuous improvement, not commuting across the factory.
To combat this, we prioritised a golf buggy—allowing engineers to quickly transport themselves and their tools around the factory, reducing downtime and increasing efficiency.
To learn more about our approach to engineering support, check out our About Us page.
2. Versatile Tool Kits & Rolling Tool Chests
Next, we needed to ensure engineers had access to comprehensive tool kits that provided maximum versatility. This would enable them to complete most jobs without needing to return to the workshop for extra tools.
To achieve this, we designed rolling tool chests, which could be easily transported to wherever the engineers were needed. Additionally, we created dedicated tool kits for High-Care production areas to prevent cross-contamination by ensuring that tools remained within specific zones.
For insights on best practices in engineering efficiency, you can explore The Manufacturer, a trusted source for industry trends.
3. Optimised Engineering Workshop Layout
An efficient engineering workshop requires strategically placed tools and enough bench space to accommodate different tasks.
We implemented a shadow board wall around a 2m-square workbench, ensuring that all necessary hand tools were within arm’s reach. Given that this factory primarily worked with valves and pumps, we stocked the shadow boards with spanners, screwdrivers, sockets, and Allen keys—eliminating the need for engineers to search for tools or walk unnecessary distances.
To learn more about how we have helped optimise engineering spaces, visit our Latest Engineering Projects.
For an in-depth look at workshop design principles, we recommend this guide from Engineering.com.
4. In-Workshop Engineering Stores
Fortunately, we had sufficient space to integrate engineering stores within the workshop itself. To maximise efficiency, we installed space-saving storage systems to keep spare parts neatly organised while using the least amount of floor space possible.
To understand how storage solutions impact workshop efficiency, check out this article on lean manufacturing.
By implementing these solutions, we ensured the engineering team could operate efficiently, reducing wasted time and improving overall productivity.
If you are looking for expert engineering solutions, feel free to contact us.
Key Takeaways
🔹 Minimise Walking Time: Provide mobile solutions like golf buggies and rolling tool chests. 🔹 Optimise Tool Access: Implement shadow boards and strategically positioned workbenches. 🔹 Locate Stores Efficiently: Where possible, integrate engineering stores within the workshop. 🔹 Maximise Space Utilisation: Use space-saving storage solutions to keep tools and parts organised.
By focusing on ergonomic design and efficiency, we transformed this engineering workshop into an optimised, high-performance workspace.
For additional insights on best practices in engineering workshops, check out this article on The Engineer.