Always interesting to have a nose around a fellow woodies workshop and even after a couple of decades in the business I'm always open to new ideas and techniques. "Lean" seems to be a good way forward for us, so we'll filling bins over the holidays. All the best for the 2021...
The shop is looking great Alastair - you and Brady have come a long way since taking it over. Thanks for th3 shout-out and all the best for 2021 and beyond!
Glad you think so Darren and it’s no trouble at all giving you a little shout out at the end - I remain very grateful for your contribution in setting the place up!
My job is teaching and implementing Lean in aerospace manufacturing so great you are using these techniques in your business. Keep experimenting and trying ideas you’ll make great progress
My advice would be: 1. Stick with one teacher but reads lots. Most Lean teachers have their preferences about tools to use and to many confuse people when the tools have actually come from the same source 2. Understand detailed std work and how to do time observations. Nothing will let you see more about waste and improvement. Most teachers miss the importance of it and the benefits of being very detailed 3. Learn to problem solve properly. You will be making errors and these can be eliminated one at a time. Last piece is look at this book www.lean.org/Bookstore/ProductDetails.cfm?SelectedProductId=410 Jim Lancaster wrote the book but was taught by my teacher. It teaches std work, visual mgmt. and std mgmt.
Looks brilliant so far. It's would be great to see this workshop running in another video. I have tried LEAN concept to furniture workshop, but that was so tough because all different components of a furniture piece are processed in different steps. That means you need more space and trolleys to store and keep the components in queue prior to moving into next steps. I see you got a lot colorful stuffs , they are probably the signals for the priority or operation order. Looks good !!! But, as you know , as market is not stable , your clients change product design time by time. I don't know how your LEAN workshop adapts that. Thank you for posting this video. People will learn a lot from that
Parts shouldn’t be say waiting for long on a cart. Part of the lean idea is ‘pull’ not ‘push’. We shouldn’t be getting backed up by over production or cutting things too soon. These days, on a typical project which has sprayed external parts and melamine internals, the MDF 2 piece doors are made first on the cnc, then straight to assembling, sanding, spraying. Then any other MDF spayed parts follow close behind. But the melamine carcase parts are usually manufactured and edgebanded the day before everything is sent out for installation.
@@Alastair_Freebird , Thanks John for quick reply. That sounds good. But I don't know if it can work in mass production and fast pace environment. I'll keep learning from what you have done.
Yes it laid a great foundation for the business! We recently got better dust extraction and ducting. We are just now discussing how we would fit a bigger cnc machine in - by pushing the spray booth enclosure further down and putting the 2 big workbenches against the window wall
@@Alastair_Freebird yes! Great to hear. That first stage was the “foundation” stage. 3F = factory flow foundations. Now you are looking at the next stage. Final stage is excellence. World class excellence thought Lean.
@@TheJoineryCoach Things are moving forward here at a pace now! The physical business remains necessary as a sort of lean showcase, without sucking me in too much to bespoke fitted furniture, but mainly producing repeatable products. The SketchUp/CabinetSense training work has now reached a tipping point where I am approached for training at a higher hourly rate than I can command for the manufacturing work, so I just can't justify sidlining it anymore. I will soon be taking up the offer of being the UK distributor of CabinetSense - the demand for SketchUp-based parametric CNC software is huge over here, as word is spreading that it now competes with the big players. We are also launching a parametric web based ordering system for shaker doors, and the timing is good because that looks set to be entirely delegated once it gets flowing. We officially launch that at a trade show in mid May. We are also working on a deal for me to have a percentage of sales through that system as it rolls out worldwide. So alongside the alcove cabinets (which we are circling back to as a priority in our marketing again), it is starting to look viable for the business to run with reduced input from me so I can pursue the more profitable avenues, while keeping a tidy and secure business providing fulfilling employment to my team. Our time with the Joinery Coach really helped us put some good systems in place. It was also good that I stopped and drew a line under that period, to more freely pursue my own priorities for my business, which looks set to reap dividends. So it's all coming good now 👍
Tip for your Kanban cards and how to get them to the next level. Simple four step implementation. 1) Use the card itself as the reorder signal. Specifically meaning that you either scan or take a photo of the card and send it to the vendor. 2) You will need to discuss this "authorization" signal with your vendors before hand so that their staff accepts the email/text/fax/scan as the authorization by your company to produce or release the next order. 3) Once the scan authorization is complete, put the card in a small box where you receive materials back at the front end of your process. 4) When the items are received and put away, bring the card back to the bin. Remember, kanban basically translates to the word, "signal". The JIT method used at Toyota to develop what was identified as "kanban" used the cards as a method of metering or controlling the flow of materials in their supply chain. The card is more than just information but a delegation of purchasing/producing authorization for you as a manager to drive control through all levels of the organization and keep costs under control and material on hand at the right times.
I would recommend getting serious about your floor tape - what colors mean what and where things go with “flow” in mind - where the workpieces go from operation to operation. Keeps the layout from getting cluttered! Include a hold area too. Awesome job so far!
Thank you. We’ve started using floor tape around the cnc. Always so much more we could do! Achieving simplicity and flow is hard work! What’s your background in this area?
Fabulous lean shop. I used to run a plant that made custom tables, booths, and bars, and came to many of the same conclusions you ended up with. Love your comments about "experimenting", and usage of kanban for a small shop. Good luck to your business!
I think it’s essential to experiment and find what works for you, there are lots of different ways to implement things. The component storage area and Kanban system has taken especially long to finalise - one of those things that may seem simple when finished but a lot of thought went into the choice of boxes, storage area, even the size abs layout of the cards!
@@Alastair_Freebird It's truly a great use of space. As a lean nerd myself, you have a great layout. Clear inbound and outbound lanes, organized and combined work areas, clear zones that group work where you can, and not move too far from zone to zone otherwise, good 5S, cart usage, etc. I think you are well on your way. Good use of space. If you ever figure out the sanding area well you are going to be ahead of most shops.
I really appriciate seeing your progress and hearing your reasoning behind. A few lean recommendations: 1. Put som magnets on the pusher stick so you can attach it to some good place. 2. Think about the workflow and movement when using drills and impact driver. If you have to change drills/bits a lot - get more tools and mark them on the back with Pozidrive 2 for example. Consider to have a mobile cart for drills so you can keep them close to the workspace. 3. The canban cards can have a QR code with the website adress on it- so you can order even quicker. 4. Consider markings on the floor for carts so it's obvious where they shold be kept when not in use. 5. The cable to the big saw should be below the floor surface, big risk for damage to the cable now... 6. Maybe have som electricity above work surface? Cable reel automatic maybe? 7. Paper rolls should have a holder, especially in package area. 8. If you increase volume in the future - consider is you shold get some special packing for cabinet doors for example to avoid wasting time and damaging goods in transportation. Looking forward to see what you will improve next. Merry Christmas from Sweden
Great to see this come together for you I'm one step behind you in the middle of building a 4500sq ft workshop after years of dreaming months of planning hopefully few more weeks of work I should be on the home run. Have a good Christmas look forward to seeing more from you in the new year
@@Alastair_Freebird you mentioned about have a coach helping with the layout and flow of the workshop, would you say it's make a big difference to your thinking on the layout and flow, I'm just asking lots of other joiners to pick up tip and tricks but wondering if I should get some one like that involved
Honestly I don’t think I could have taken a step like this without an experienced guide to lean on. Too much of it is new to me - I mean I never even worked in anyone else’s workshop before embarking on a career in woodworking so had very little experience to draw on; let alone getting to grips with ‘Lean’. I have dabbled with business networking groups, mentors and coaches over the years but always felt they weren’t specific enough to my industry to help with the most problematic gaps in my knowledge. Bruce the Joinery Coach and his team have both knowledge and credible experience and success in making exactly my kind of business work. It takes a shift in mindset to see value in the fairly significant costs, but after hearing the common story of people trying to scale only to fail, I knew I needed to invest in support. It’s a long term thing which I don’t expect to reap the rewards from immediately. www.thejoinerycoach.com/
Great thanks for that. I cover a wide range of joinery and often wonder if I should narrow it down but then I love the challenge of the range I do from built in to stair doors windows some free standing furniture to heritage buildings . And at this stage 17yrs in I'm 99% repeat work iv a few who won't allow anyone else do there work to the point some have waited 10-12 months to get to them don't want to leave them out by dropping their line of work. Thanks again have a good and safe Christmas
I work in with lean principles within the hse procurement (Irish health service).. I'm also a hobbyist wood worker.. I've been thinking how to combine my 2 skillsets.. This has given me some ideas. I like how you have implemented the 2 bin system... Thats what I implemented across my areas.. We made savings of over 30%. And the stock takes have reduced by 70%..
Congrats. Must be a helluva feeling walking into there for you. That wadkin saw is a beast! Didn’t know they were still manufacturing. Strange to see an entire workshop/factory setup without one vise in sight. Best of luck this year
Thanks for your enthusiasm! It still feels like a mountain to climb - we have the space now but other elements of the business still need to catch. Still, it’s good to step back and be grateful for how far we’ve come!
Alastair, a masterclass in building an efficient manufacturing business - well done, an impeccable implementation. The only remaining opportunity I could see was the shipping step at the end. Maybe invest in some small scale pallets and a micro forklift to drop a job consignment straight into the back of the van. Fantastic to see you back on UA-cam, you clearly produce top-class content and many people will derive practical benefit. I do think you are missing a trick and revenue from not investing more on UA-cam. Good luck with the new facility and a happy new year.
Thanks for these thoughts Lester! Some kind of powered forklift would be good in future. 2!of those simpler wheeled carts are built with the platform at same height as the van floor. So after packaging parts at the assembly bench they can be loaded onto the cart at the side of the bench then easily all shunted into the van
Hi great layout of your wood working shop. I’m about to reopen a wood shop next year here in New Zealand. I’ve heard a lot of great things about lean including working for other cabinet shops that have this way of doing things.
They are simply made from second hand metal racking which I got from John Burley’s in Swinton. If you fit only the rear cross members and not the front ones, then you can get short cantilevered arms that hook over the rear ones and stick forward. Then I simply screwed some vertical boards to those arms to create more distinct partitions
Well now... yes the CNC will be a total game changer and I expect we will completely revise a lot of our methods accordingly - starting with most probably replacing pocket hole joints with the Lamello Cabineo fixings
Thought I was going to see a small, minimalist workshop for ideas on finalizing my 400 sq ft shop. Not the same kind of lean that I was expecting but a very nice shop!
Really excellent setup ,very professional , I have been trying for years to work a clean lean system applied to site joinery it’s not easy to get everybody on board especially some of the older hands but it works well when you do . All the best for Christmas and the new year
Shame you are not in my neck of the woods as I would happily assist you in removing anything left in your over 3 weeks scraps bin. I bet there's a fair bit of useful offcuts there.
Yes definitely there would be useful boards in there. We are thinking of advertising on Facebook. It would simply be ‘come at this time (maybe a 1 hour slot) to take what you want, and after that it’s all going in the skip’. Got to start getting ruthless to avoid the clutter building up again.
Thanks for your content this past year Alastair. Been great to follow your progress and the amount of info you share is why I love your channel. Keep it up and have a wonderful Xmas with your family and let's hope we all have a better 2021!
Anything in a blue box has been tried and tested as a regularly used standard component, so is likely to be used and refilled fairly regularly. So, I mean, we’ve already done a lot of whittling down of old things we used to store, in the process of moving from the old garage workshop to this workshop (I found all sorts of weird and wonderful and completely unused components!). Items which are still occasionally useful are kept in other boxes nearby but not in that main unit. For them, you are right that it would be good to label them with the last used date and try to be ruthless and dispose of them if not used after 6 months.
@@Alastair_Freebird when I was younger I worked for a company that reported on everything they even had a report for how many new reports were made each month. It's a shame the first lockdown happened as I was looking forward to coming up and helping out but being down south couldn't stay anywhere. Hopefully next year I may be able to come and help if still needed
When you have off cut pieces reach the 4th month of non use, do you ever cut and glue the off cuts into composit pieces that would be of more useful dimensions?
Occasionally for solid oak board only. For mdf etc the work involved is not worth the cost of the board (and it’s harder to get a perfect joint that is strongly glued and that won’t show a slight seam through a smooth painted finish)
Hi Alan, I had a look at the hammer machines a few years ago before getting the bigger workshop and I just decided to bide my time until I knew what space I had to work with. When the time came, I decided to go second hand on the basis I could get a better machine - more for my money - but it was a bit of a double edged sword, and I would be really recommend buying second hand unless it’s from an established reputable dealer who you know will give you back up and servicing if you have issues. I got a Wadkin CP32 and had a few issues with it but it is now well set up and working fairly well for us (look for a video on my channel called ‘how to square a panel saw’)
Thank you for the tour. I’ve been a keen observer of production principles for most of my career. Fascinating stuff. Reducing wasted motion has always been my “specialty” 😏. I’m curious what ambient temperature you keep in your shop. Do warm other liquids like glue? Or just the sprayer/paint?
Hi, well, the ambient temperature is pretty much the same as outside this time of year! We really need to get some proper space heating (a large woodburner is the obvious solution) but the budget cant stretch to that yet, so i'm think we save up for it in the coming year. It would definitely be good to not let the glue and other things freeze!
The woodshop looks great. Do you use any software, apps, etc. to manage your work or white board is enought? How you deal with many projects at the same time?
Yes we rely a lot on ServiceM8 (though it has plenty of niggles and flaws) and I also use Airtable. And Google chat to communicate with the team. I have gone through so many apps trying to find ‘the one’. Trello, Nimbl, various others. None of them are perfect…. Unless you spend a LOT of money on an industry specific solution aimed at bigger businesses (like Jobman software) or pay to make a bespoke app. But in any case, it’s only ever as good as the way you set it up and how you use it. Eventually you just have to choose an imperfect system, make it work for you as best you can, and always strive to keep it simple. The precursor to it all is clarifying each step of your business process flow.
I thought this lean stuff wouldn’t matter to me with only 250 square feet, but it’s probably even more important - especially dealing with waste. There’s nowhere to store it! Thanks for all that you do for us beginners, and best wishes for Christmas.
Does an internal office space need to be built to uk regs as I’ve got an industrial unit but need to build and office in here in the most cost effective way
Well, we ended up buying a second hand shipping container office (already fitted with windows and door, basic internal lining and insulation and a couple of electrical heaters). That was a good decision. Keeps the office away from the noise of the workshop.So long as you have space for it outside
Ayoo! Just learned about lean principles and six sigma training through, my college in California this last quarter. Thanks for implementing that into the video! It would be awesome to see more of it!
Lean sounds like a marketing manager term. Common sense is far cheaper. Our workshop is setup similar but with a secondary line of real wood, (rip,crosscut,surface and four cutter) much like your cnc will be. I suspect you’ll be reducing your kreg station,or moving it to your side and placing your planner/thicknesser in that area (effectively creating 3 initial lines from raw materials. There’s no way you’re going to be able to process timber in the corridor because that will be full of finished cabinets in no time at all lol. Also, do you use a bench hook style jig for lamello/domino or just reference using the machines fence?
Lean is a way of thinking that goes way beyond my own common sense but I see what you’re saying about keeping it simple. So I think your ‘common sense’ is probably informed by your own experience. I think efficiency is also about focus and reduction - we specialise in panel based work which almost never requires the planet thicknesser but it seems worth keeping for the occasional need.
Lean is a japanese system that was created from Toyota manufacturing and they got the idea from Ford who created the modern manufacturing line. Lean is a system and it could be described as common sense as well.
Currently we do. Plus bedrooms. I often ask myself whether I should be doing kitchens and other bigger jobs but actually there’s a lot to be said for specialising. The work is out there. We are very fast and efficient at alcoves now, and able to charge good rates. I’m about o advertise for an installer.
@@Alastair_Freebird yeah I wonder if the market is big enough here in ireland. Companies that specialize seem to do well. I am involved in the kitchen industry myself. Lot to be made in it but a lot to be lost also.
Great work Alistair, hope your hard work pays off and this part of your adventure really helps streamline things and progress your business. Been looking at the Auer packaging toolboxes as an alternative to Systainers, how do you find them?
I was waiting for someone to ask me that! A future video subject perhaps but in summary the FESTOOL systainers are more durably made and the locking mechanism is more reliable. I would definitely say stick with systainers for site work - in and out of the van etc. I do however like the transparent lidded boxes and the various screw box inserts, and their 3-slot systainer sized holders.l, but mainly for workshop organisation.
Hi Chris I'm just a diyer getting into woodworking but I ordered some systainers and wasn't impressed with the quality for the price so sent them back. I have some Auer tool boxes and they seem comparable in quality. I am based in my garage so if Alistair thinks they are less durable they probably are but for half the price I think they are very good.
@allthegear they aren’t bad, but I found that the spring clip style locking mechanism between boxes was a little prone to popping out with vibration (for example when wheeling a tall stack around or accidentally bumping a tall stack that you are carrying out of the van), whereas I find the turn clip locking mechanism on the systainers very solid and reliable. Also one of my Auer boxes (the type that receives the three trays) arrived with a sort of loose back panel, which seem thin and relied on fragile clips to connect to the top and bottom structure
@@allthegearuk Great to know, thanks for the input because I’m only a DIYer/Garage based but starting to take the woodwork side of things more seriously. Managed to snap up a couple of the bigger Dewalt t-staks to home some of my gear and stumbled upon the Auer stuff but haven’t been able to find much about it. Out of interest did you buy yours from AllTheGear?
@@chrissnowden7078 I got mine from Auer. If you after in the UK it's quite easy to order online. Look at their website they have lots of info and technical drawings of items. I am planning to fit out the workshop/garage with Auer euro boxes mostly with a few toolboxes for moving tools to jobs around the house or to friends/family. There are a few videos on UA-cam about them but they are on French or German but might be useful.
Random question - I have a customer who wants some full height wardrobes and is determined to have the doors from 18 mm mdf made with cnc . I’m concerned they will bow being so tall and around 550 wide ?
Hi, it wasn’t at first and I was worried is made a bad purchase but then I got it properly squared up and it cuts well now, except that a bit of wear on the crosscut fence can mess up the squareness on smaller cuts
This Instagram highlight shows the whole process of squaring up a panelsaw instagram.com/s/aGlnaGxpZ2h0OjE3ODk3NDg5Nzg1NzIwODkx?igshid=1o4rj6q19v02o&story_media_id=2460985356675166148
No I mean through decades of use, the crosscut fence is no longer perfectly flat and straight along its length, where you push the edge of the board up against it - it is slightly worn towards the blade so a long straight edge pushed tight against it will show a very slight tapering gap toward the blade end of the fence. So when the fence is squared up for a large board, a smaller board that only makes contact with the worn section will be tilted slightly off square
@@Alastair_Freebird yes, literally just finished the video you sent me. Great video. Thank you for that. You should put that on UA-cam as well, it’s great info you have there. I’ve also heard that a .002 “toe out” between the blade and the rip fence is good for safety.
Looks very stocked! Looks brilliant. Does this mean you will be machining more of your doors instead of outsourcing to a cnc machinist ? Just being nosey! Haha
Oh yes, once we get the CNC machine we will certainly do all our own shaker doors using that solid panel cut our method (and maybe doors for others too!)
Looking great Alistair 👍 I reckon next year is gonna be a good year for Freebird. The time and money you have invested in the new shop after all the crap we've been through this year is a true testament to your mentality and determination 👏 Matt @bespokedhandmadefurniture
nice video thanks for sharing. If you are interested I also have some lean ideas on my 'malcolm mcgrath' youtube channel. For example overhead boom in assembly area. Cheers
Do you mean you think there is unnecessary transportation etc in our current plans? Please elaborate, show me where to improve and I will happily buy you a coffee!
@@Alastair_Freebird I don't drink coffee, just a joke. Just saying these lean recommendations are common sense. I used to do general home remodeling but it was too competitive. I switched to historic wood window restoration with linseed oil paint. I now have a niche in the already less competitive window restoration market, have differentiated myself and work mostly at home. I also make wood storm windows and finish them with linseed oil paint. Lean is fine but finding less competitive niches where lean matters less is better.
Apologies if I took this too seriously! Still, for me, learning Lean methodology has been a bit of a revelation. What I previously thought of as ‘waste’ I now see is not that at all, and what I previously thought of as efficient I now realise is often not! For example I used to think it was wasteful to throw away offcuts. I had to learn the hard way that the real waste is the storage space, distracting clutter, and time that those unused bits of wood take up in a workshop when they hang around for years! ‘Lean’ thinking gave me the language and the eyes to see what was already happening in my old workshop and acknowledge it as counter productive. Conversely, where I was spending a lot of time creating systems that were never fully implemented, or not fit for purpose, I’ve been able to understand these as the waste of overprocessing. The considerable time we spent planning the flow of this workshop, and building equipment such as those partitioned carts that saves both labour effort and time is already paying dividends when work is flowing through, but perhaps it’s harder to see when they are just sat there in an sort workshop for the Christmas shut down!
@Richard McKrell Lean is a modular approach and it is systematic as well. It is a way of thinking and you could just as easily describe it as common sense but it does give you a frame of mind and it also means you can implement it in a business and people can understand it hence why it is easy to implement.
Do you need to pay a coach to tell you to put your saw and racks near the door and to build some trolleys? This is all just common sense. Sounds like a waste of money to me. 🤣
There’s a little more to it than that 😁 but actually sometimes I do benefit from having a coach simply to help me see the wood from the trees and get my priorities right in the mad rush of day to day work - too many businesses don’t do the obvious because they’re too caught up in day to day fire fighting!
Always interesting to have a nose around a fellow woodies workshop and even after a couple of decades in the business I'm always open to new ideas and techniques. "Lean" seems to be a good way forward for us, so we'll filling bins over the holidays. All the best for the 2021...
It feels good to throw things away!
instablaster.
I use the same twin slot racks as you. I recently added 22mm pipe insulation and they work a treat. No more scratched panels.
I’ve been meaning to get around to doing that!
Really great video, thank you. The vertical storage for cutted boards, and horizontal for new boards is also a very good tip.
That and making use of wheeled carts can save a lot of time
The shop is looking great Alastair - you and Brady have come a long way since taking it over. Thanks for th3 shout-out and all the best for 2021 and beyond!
Glad you think so Darren and it’s no trouble at all giving you a little shout out at the end - I remain very grateful for your contribution in setting the place up!
My job is teaching and implementing Lean in aerospace manufacturing so great you are using these techniques in your business. Keep experimenting and trying ideas you’ll make great progress
Lots still to learn! Advice welcome
My advice would be:
1. Stick with one teacher but reads lots. Most Lean teachers have their preferences about tools to use and to many confuse people when the tools have actually come from the same source
2. Understand detailed std work and how to do time observations. Nothing will let you see more about waste and improvement. Most teachers miss the importance of it and the benefits of being very detailed
3. Learn to problem solve properly. You will be making errors and these can be eliminated one at a time.
Last piece is look at this book
www.lean.org/Bookstore/ProductDetails.cfm?SelectedProductId=410
Jim Lancaster wrote the book but was taught by my teacher. It teaches std work, visual mgmt. and std mgmt.
Looks brilliant so far. It's would be great to see this workshop running in another video. I have tried LEAN concept to furniture workshop, but that was so tough because all different components of a furniture piece are processed in different steps. That means you need more space and trolleys to store and keep the components in queue prior to moving into next steps. I see you got a lot colorful stuffs , they are probably the signals for the priority or operation order. Looks good !!! But, as you know , as market is not stable , your clients change product design time by time. I don't know how your LEAN workshop adapts that. Thank you for posting this video. People will learn a lot from that
Parts shouldn’t be say waiting for long on a cart. Part of the lean idea is ‘pull’ not ‘push’. We shouldn’t be getting backed up by over production or cutting things too soon. These days, on a typical project which has sprayed external parts and melamine internals, the MDF 2 piece doors are made first on the cnc, then straight to assembling, sanding, spraying. Then any other MDF spayed parts follow close behind. But the melamine carcase parts are usually manufactured and edgebanded the day before everything is sent out for installation.
@@Alastair_Freebird , Thanks John for quick reply. That sounds good. But I don't know if it can work in mass production and fast pace environment. I'll keep learning from what you have done.
This popped up in my feed today. Looking back it was great progress made ! It was fun and enjoyable working with you on this
Yes it laid a great foundation for the business! We recently got better dust extraction and ducting. We are just now discussing how we would fit a bigger cnc machine in - by pushing the spray booth enclosure further down and putting the 2 big workbenches against the window wall
@@Alastair_Freebird yes! Great to hear. That first stage was the “foundation” stage. 3F = factory flow foundations. Now you are looking at the next stage. Final stage is excellence. World class excellence thought Lean.
@@TheJoineryCoach Things are moving forward here at a pace now! The physical business remains necessary as a sort of lean showcase, without sucking me in too much to bespoke fitted furniture, but mainly producing repeatable products. The SketchUp/CabinetSense training work has now reached a tipping point where I am approached for training at a higher hourly rate than I can command for the manufacturing work, so I just can't justify sidlining it anymore. I will soon be taking up the offer of being the UK distributor of CabinetSense - the demand for SketchUp-based parametric CNC software is huge over here, as word is spreading that it now competes with the big players. We are also launching a parametric web based ordering system for shaker doors, and the timing is good because that looks set to be entirely delegated once it gets flowing. We officially launch that at a trade show in mid May. We are also working on a deal for me to have a percentage of sales through that system as it rolls out worldwide. So alongside the alcove cabinets (which we are circling back to as a priority in our marketing again), it is starting to look viable for the business to run with reduced input from me so I can pursue the more profitable avenues, while keeping a tidy and secure business providing fulfilling employment to my team. Our time with the Joinery Coach really helped us put some good systems in place. It was also good that I stopped and drew a line under that period, to more freely pursue my own priorities for my business, which looks set to reap dividends. So it's all coming good now 👍
Tip for your Kanban cards and how to get them to the next level. Simple four step implementation. 1) Use the card itself as the reorder signal. Specifically meaning that you either scan or take a photo of the card and send it to the vendor. 2) You will need to discuss this "authorization" signal with your vendors before hand so that their staff accepts the email/text/fax/scan as the authorization by your company to produce or release the next order. 3) Once the scan authorization is complete, put the card in a small box where you receive materials back at the front end of your process. 4) When the items are received and put away, bring the card back to the bin.
Remember, kanban basically translates to the word, "signal". The JIT method used at Toyota to develop what was identified as "kanban" used the cards as a method of metering or controlling the flow of materials in their supply chain. The card is more than just information but a delegation of purchasing/producing authorization for you as a manager to drive control through all levels of the organization and keep costs under control and material on hand at the right times.
Thank you I appreciate gaining these kind of insights from more experienced commentors it’s valuable to me 👍
Best of luck with the new workshop, the layout looks great. thanks for sharing.
I would recommend getting serious about your floor tape - what colors mean what and where things go with “flow” in mind - where the workpieces go from operation to operation. Keeps the layout from getting cluttered! Include a hold area too. Awesome job so far!
Thank you. We’ve started using floor tape around the cnc. Always so much more we could do! Achieving simplicity and flow is hard work! What’s your background in this area?
Well done on taking the plunge and best of luck
Very well thought out, lots of efficiency tips I can glean from this quick run-through, thanks for posting!
Thanks I appreciate you commenting!
Fabulous lean shop. I used to run a plant that made custom tables, booths, and bars, and came to many of the same conclusions you ended up with. Love your comments about "experimenting", and usage of kanban for a small shop. Good luck to your business!
I think it’s essential to experiment and find what works for you, there are lots of different ways to implement things. The component storage area and Kanban system has taken especially long to finalise - one of those things that may seem simple when finished but a lot of thought went into the choice of boxes, storage area, even the size abs layout of the cards!
@@Alastair_Freebird It's truly a great use of space. As a lean nerd myself, you have a great layout. Clear inbound and outbound lanes, organized and combined work areas, clear zones that group work where you can, and not move too far from zone to zone otherwise, good 5S, cart usage, etc. I think you are well on your way. Good use of space. If you ever figure out the sanding area well you are going to be ahead of most shops.
That’s all very encouraging thank you
I really appriciate seeing your progress and hearing your reasoning behind.
A few lean recommendations:
1. Put som magnets on the pusher stick so you can attach it to some good place.
2. Think about the workflow and movement when using drills and impact driver. If you have to change drills/bits a lot - get more tools and mark them on the back with Pozidrive 2 for example. Consider to have a mobile cart for drills so you can keep them close to the workspace.
3. The canban cards can have a QR code with the website adress on it- so you can order even quicker.
4. Consider markings on the floor for carts so it's obvious where they shold be kept when not in use.
5. The cable to the big saw should be below the floor surface, big risk for damage to the cable now...
6. Maybe have som electricity above work surface? Cable reel automatic maybe?
7. Paper rolls should have a holder, especially in package area.
8. If you increase volume in the future - consider is you shold get some special packing for cabinet doors for example to avoid wasting time and damaging goods in transportation.
Looking forward to see what you will improve next.
Merry Christmas from Sweden
Great advice thank you!
CNC will be great, such amazing machines. If a part has to be remade one can just bring up the file and viola.
Keep on "leaning", it's the way to go.
True! And it happens quite often…
Great to see this come together for you I'm one step behind you in the middle of building a 4500sq ft workshop after years of dreaming months of planning hopefully few more weeks of work I should be on the home run. Have a good Christmas look forward to seeing more from you in the new year
Wow that sounds like a huge task!
@@Alastair_Freebird you mentioned about have a coach helping with the layout and flow of the workshop, would you say it's make a big difference to your thinking on the layout and flow, I'm just asking lots of other joiners to pick up tip and tricks but wondering if I should get some one like that involved
Honestly I don’t think I could have taken a step like this without an experienced guide to lean on. Too much of it is new to me - I mean I never even worked in anyone else’s workshop before embarking on a career in woodworking so had very little experience to draw on; let alone getting to grips with ‘Lean’. I have dabbled with business networking groups, mentors and coaches over the years but always felt they weren’t specific enough to my industry to help with the most problematic gaps in my knowledge. Bruce the Joinery Coach and his team have both knowledge and credible experience and success in making exactly my kind of business work. It takes a shift in mindset to see value in the fairly significant costs, but after hearing the common story of people trying to scale only to fail, I knew I needed to invest in support. It’s a long term thing which I don’t expect to reap the rewards from immediately. www.thejoinerycoach.com/
Great thanks for that. I cover a wide range of joinery and often wonder if I should narrow it down but then I love the challenge of the range I do from built in to stair doors windows some free standing furniture to heritage buildings . And at this stage 17yrs in I'm 99% repeat work iv a few who won't allow anyone else do there work to the point some have waited 10-12 months to get to them don't want to leave them out by dropping their line of work. Thanks again have a good and safe Christmas
nice big shop , I just went through the same sort of process refurbishing a 1500sq/ft building , you got me inspired to put that video together ...
Well done, mate. Great to see things taking off.
congratulations - onwards and upwards !
I work in with lean principles within the hse procurement (Irish health service).. I'm also a hobbyist wood worker.. I've been thinking how to combine my 2 skillsets.. This has given me some ideas.
I like how you have implemented the 2 bin system... Thats what I implemented across my areas.. We made savings of over 30%. And the stock takes have reduced by 70%..
I’m always interested to hear how others apply similar principles. It’s all very new to me
Congrats. Must be a helluva feeling walking into there for you. That wadkin saw is a beast! Didn’t know they were still manufacturing. Strange to see an entire workshop/factory setup without one vise in sight. Best of luck this year
Thanks... the Wadkin is second hand and about as old as I am!
Been looking forward to seeing your new workshop and it looks the business !, hopefully we will be seeing some new content in the near future).
That looks great. Congratulations.
I really like those wheeled carts. I'm trying to relocate currently hear on Vancouver Island.
Cart dimensions here: www.buymeacoffee.com/Freebird/vlog-19-wheeled-carts-overview
Wow, I’m witnessing such a transformation in your business it’s terrific. Wish you continued success 👍🏻👍🏻👍🏻
Thanks for your enthusiasm! It still feels like a mountain to climb - we have the space now but other elements of the business still need to catch. Still, it’s good to step back and be grateful for how far we’ve come!
Glad to see someone else in the UK has discovered Auer assortment boxes. Subscribed just for that!
It is easy to spend too much with them!
@@Alastair_Freebird very true and it's lucky the tool boxes are half the price of systainers
Alastair, a masterclass in building an efficient manufacturing business - well done, an impeccable implementation. The only remaining opportunity I could see was the shipping step at the end. Maybe invest in some small scale pallets and a micro forklift to drop a job consignment straight into the back of the van. Fantastic to see you back on UA-cam, you clearly produce top-class content and many people will derive practical benefit. I do think you are missing a trick and revenue from not investing more on UA-cam. Good luck with the new facility and a happy new year.
Thanks for these thoughts Lester! Some kind of powered forklift would be good in future. 2!of those simpler wheeled carts are built with the platform at same height as the van floor. So after packaging parts at the assembly bench they can be loaded onto the cart at the side of the bench then easily all shunted into the van
looks a great unit - about 100 steps up from a garage !
Very impressive workshop. One day....one day!
Careful what you wish for... now I’ve got to pay for it
Great Job! well done mate, you;ve come a far way just over this past year.
Thanks!
Congrats on the new space! Wishing your shop all the best in 2011!
Thanks very much!
Best of luck with the new shop looks great 👍
Thanks!
Hi great layout of your wood working shop. I’m about to reopen a wood shop next year here in New Zealand. I’ve heard a lot of great things about lean including working for other cabinet shops that have this way of doing things.
Paul Akers at Fast Cap models lean very well
Great to see how far you’ve come this year Alastair. The workshop is looking great!
Thanks Morgan!
Glad to see you finally set up, looks great 👍🏻
Some serious work there mate
Congrats
Thanks
Would you share the drawings for you offcut sheet racks if available. These are fantastic looking and a really good solution.
They are simply made from second hand metal racking which I got from John Burley’s in Swinton. If you fit only the rear cross members and not the front ones, then you can get short cantilevered arms that hook over the rear ones and stick forward. Then I simply screwed some vertical boards to those arms to create more distinct partitions
*Very nice you workshop 🤗🤗🤗*
Thank you
When you get your CNC router you will be able to cut your pocket holes on that. Saves a useful bit of time and cuts out a separate operation.
Well now... yes the CNC will be a total game changer and I expect we will completely revise a lot of our methods accordingly - starting with most probably replacing pocket hole joints with the Lamello Cabineo fixings
Thought I was going to see a small, minimalist workshop for ideas on finalizing my 400 sq ft shop. Not the same kind of lean that I was expecting but a very nice shop!
Hopefully there are some ideas you can still use - waste management is especially important I think
Really excellent setup ,very professional , I have been trying for years to work a clean lean system applied to site joinery it’s not easy to get everybody on board especially some of the older hands but it works well when you do .
All the best for Christmas and the new year
Yeah, I decided I wanted to get good practises well established before bringing any more staff on board!
Looks like an amazing space.
Brilliant progress to the business 👍 Good luck
Thanks
Well done, looks very efficient. I'm on the verge of taking on a unit so I've been following your progress 👍
I hope some of our experience is helpful.
Looks amazing Alastair, really really unbelievable job mate, you deserve this spaces and more, from a fellow carpenter to another, Sam hertfordshire
Thanks Sam!
Shame you are not in my neck of the woods as I would happily assist you in removing anything left in your over 3 weeks scraps bin. I bet there's a fair bit of useful offcuts there.
Yes definitely there would be useful boards in there. We are thinking of advertising on Facebook. It would simply be ‘come at this time (maybe a 1 hour slot) to take what you want, and after that it’s all going in the skip’. Got to start getting ruthless to avoid the clutter building up again.
Thanks for your content this past year Alastair. Been great to follow your progress and the amount of info you share is why I love your channel. Keep it up and have a wonderful Xmas with your family and let's hope we all have a better 2021!
Thanks so much for commenting, I really value the encouragement of feedback like this. Hoping with you!
Looking good so far 👍
Thanks
Excellent
Glad you think so!
Don't forget fire detection, security and CCTV. Oh and good (tested) backups for your IT!
Good points!
@@Alastair_Freebird This should be an eye opener for many in the wood working business:
ua-cam.com/video/3aOhfzmryss/v-deo.html
Have you looked at microjig's machfit 360 system. Alternative to t track and mft system.
Yes! Someone showed me that on Instagram. Looks great
Awesome!!
Do you put the last order date in the parts bins similar to the material storage so if something isn't ordered in a year you get rid of it?
First to comment again Sam, even at this time of night!
Anything in a blue box has been tried and tested as a regularly used standard component, so is likely to be used and refilled fairly regularly. So, I mean, we’ve already done a lot of whittling down of old things we used to store, in the process of moving from the old garage workshop to this workshop (I found all sorts of weird and wonderful and completely unused components!). Items which are still occasionally useful are kept in other boxes nearby but not in that main unit. For them, you are right that it would be good to label them with the last used date and try to be ruthless and dispose of them if not used after 6 months.
@@Alastair_Freebird when I was younger I worked for a company that reported on everything they even had a report for how many new reports were made each month. It's a shame the first lockdown happened as I was looking forward to coming up and helping out but being down south couldn't stay anywhere. Hopefully next year I may be able to come and help if still needed
Very nice! (from Los Angeles)
Thank you!
Lovely!
Thanks
Looks great! Where did you pick up those big blue workbenches? I’ve been looking for a metal 4’ x 8’ workbench for awhile now.
From this place: ua-cam.com/video/LecVHRJxGc0/v-deo.html
When you have off cut pieces reach the 4th month of non use, do you ever cut and glue the off cuts into composit pieces that would be of more useful dimensions?
Occasionally for solid oak board only. For mdf etc the work involved is not worth the cost of the board (and it’s harder to get a perfect joint that is strongly glued and that won’t show a slight seam through a smooth painted finish)
Congratulations on the new shop. Just a FYI it won't be long until you run out of space.
Maybe... I really don’t want to run a big business with lots of staff though. I want to keep it tight.
Hi Alistair, I can see that you didn’t go with the Hammer saw what did you decide on instead and why?
Hi Alan, I had a look at the hammer machines a few years ago before getting the bigger workshop and I just decided to bide my time until I knew what space I had to work with. When the time came, I decided to go second hand on the basis I could get a better machine - more for my money - but it was a bit of a double edged sword, and I would be really recommend buying second hand unless it’s from an established reputable dealer who you know will give you back up and servicing if you have issues. I got a Wadkin CP32 and had a few issues with it but it is now well set up and working fairly well for us (look for a video on my channel called ‘how to square a panel saw’)
very nice
Thank you for the tour. I’ve been a keen observer of production principles for most of my career. Fascinating stuff. Reducing wasted motion has always been my “specialty” 😏.
I’m curious what ambient temperature you keep in your shop. Do warm other liquids like glue? Or just the sprayer/paint?
Hi, well, the ambient temperature is pretty much the same as outside this time of year! We really need to get some proper space heating (a large woodburner is the obvious solution) but the budget cant stretch to that yet, so i'm think we save up for it in the coming year. It would definitely be good to not let the glue and other things freeze!
The woodshop looks great. Do you use any software, apps, etc. to manage your work or white board is enought? How you deal with many projects at the same time?
Yes we rely a lot on ServiceM8 (though it has plenty of niggles and flaws) and I also use Airtable. And Google chat to communicate with the team. I have gone through so many apps trying to find ‘the one’. Trello, Nimbl, various others. None of them are perfect…. Unless you spend a LOT of money on an industry specific solution aimed at bigger businesses (like Jobman software) or pay to make a bespoke app. But in any case, it’s only ever as good as the way you set it up and how you use it. Eventually you just have to choose an imperfect system, make it work for you as best you can, and always strive to keep it simple. The precursor to it all is clarifying each step of your business process flow.
Bet your neighbors are so excited you have a workshop else where now
The neighbours have always been surprisingly accommodating but yes you may be right!
What material are those colored panels that are throughout the shop?
Do you remember where you got the sliding door system?
P C Henderson via Sheffix in sheffield
I thought this lean stuff wouldn’t matter to me with only 250 square feet, but it’s probably even more important - especially dealing with waste. There’s nowhere to store it! Thanks for all that you do for us beginners, and best wishes for Christmas.
John .. that is so true. The smaller shops benefit the most as the benefits are immediate
Good looking I my self stared wood 🪵 working mini workshop it not an easy thing,I also bought old machines expensive to repair I'm in south africa 🇿🇦
Nice to hear from you, good luck with it all
Does an internal office space need to be built to uk regs as I’ve got an industrial unit but need to build and office in here in the most cost effective way
Well, we ended up buying a second hand shipping container office (already fitted with windows and door, basic internal lining and insulation and a couple of electrical heaters). That was a good decision. Keeps the office away from the noise of the workshop.So long as you have space for it outside
Check out The Fire Place Chesham if you’re near herts or bucks for you wood burning stove !
Do they sell stoves that are suitable for large spaces like this?
What is the coloured material you used for your carts and workbenches?
Hi, it is a melamine faced black core mdf from Finsa. Nice to have some colour, though the core mdf material is a bit soft for my liking
Ayoo! Just learned about lean principles and six sigma training through, my college in California this last quarter. Thanks for implementing that into the video! It would be awesome to see more of it!
If he happy to hear any tips from what you’ve been learning, as it’s new to me too!
Lean sounds like a marketing manager term.
Common sense is far cheaper. Our workshop is setup similar but with a secondary line of real wood, (rip,crosscut,surface and four cutter) much like your cnc will be. I suspect you’ll be reducing your kreg station,or moving it to your side and placing your planner/thicknesser in that area (effectively creating 3 initial lines from raw materials.
There’s no way you’re going to be able to process timber in the corridor because that will be full of finished cabinets in no time at all lol.
Also, do you use a bench hook style jig for lamello/domino or just reference using the machines fence?
Lean is a way of thinking that goes way beyond my own common sense but I see what you’re saying about keeping it simple. So I think your ‘common sense’ is probably informed by your own experience. I think efficiency is also about focus and reduction - we specialise in panel based work which almost never requires the planet thicknesser but it seems worth keeping for the occasional need.
Lean is a japanese system that was created from Toyota manufacturing and they got the idea from Ford who created the modern manufacturing line.
Lean is a system and it could be described as common sense as well.
Nice setup. I have just checked your website. I am based in ireland . Do you have enough work just out of alcove units to keep you going?
Currently we do. Plus bedrooms. I often ask myself whether I should be doing kitchens and other bigger jobs but actually there’s a lot to be said for specialising. The work is out there. We are very fast and efficient at alcoves now, and able to charge good rates. I’m about o advertise for an installer.
@@Alastair_Freebird yeah I wonder if the market is big enough here in ireland.
Companies that specialize seem to do well. I am involved in the kitchen industry myself. Lot to be made in it but a lot to be lost also.
Well done I use lean at home.
I’ve heard Paul Akers talk about applying it to his whole life... can you give me some examples?
Great work Alistair, hope your hard work pays off and this part of your adventure really helps streamline things and progress your business.
Been looking at the Auer packaging toolboxes as an alternative to Systainers, how do you find them?
I was waiting for someone to ask me that! A future video subject perhaps but in summary the FESTOOL systainers are more durably made and the locking mechanism is more reliable. I would definitely say stick with systainers for site work - in and out of the van etc. I do however like the transparent lidded boxes and the various screw box inserts, and their 3-slot systainer sized holders.l, but mainly for workshop organisation.
Hi Chris I'm just a diyer getting into woodworking but I ordered some systainers and wasn't impressed with the quality for the price so sent them back. I have some Auer tool boxes and they seem comparable in quality. I am based in my garage so if Alistair thinks they are less durable they probably are but for half the price I think they are very good.
@allthegear they aren’t bad, but I found that the spring clip style locking mechanism between boxes was a little prone to popping out with vibration (for example when wheeling a tall stack around or accidentally bumping a tall stack that you are carrying out of the van), whereas I find the turn clip locking mechanism on the systainers very solid and reliable. Also one of my Auer boxes (the type that receives the three trays) arrived with a sort of loose back panel, which seem thin and relied on fragile clips to connect to the top and bottom structure
@@allthegearuk Great to know, thanks for the input because I’m only a DIYer/Garage based but starting to take the woodwork side of things more seriously. Managed to snap up a couple of the bigger Dewalt t-staks to home some of my gear and stumbled upon the Auer stuff but haven’t been able to find much about it.
Out of interest did you buy yours from AllTheGear?
@@chrissnowden7078 I got mine from Auer. If you after in the UK it's quite easy to order online. Look at their website they have lots of info and technical drawings of items. I am planning to fit out the workshop/garage with Auer euro boxes mostly with a few toolboxes for moving tools to jobs around the house or to friends/family. There are a few videos on UA-cam about them but they are on French or German but might be useful.
What brand of board is used for the carts?
They were some unusual Finsa boards I got a deal on
Random question - I have a customer who wants some full height wardrobes and is determined to have the doors from 18 mm mdf made with cnc . I’m concerned they will bow being so tall and around 550 wide ?
I prefer to use 22mm to be on the safe side. Don’t let them set the agenda against your better judgement.
Is your slider table saw accurate when it comes to squaring and processing sheet goods? Looking into these for my shop. Thx
Hi, it wasn’t at first and I was worried is made a bad purchase but then I got it properly squared up and it cuts well now, except that a bit of wear on the crosscut fence can mess up the squareness on smaller cuts
This Instagram highlight shows the whole process of squaring up a panelsaw instagram.com/s/aGlnaGxpZ2h0OjE3ODk3NDg5Nzg1NzIwODkx?igshid=1o4rj6q19v02o&story_media_id=2460985356675166148
@@Alastair_Freebird This “wear” you mention, are you talking about the adjustable stops? Thx
No I mean through decades of use, the crosscut fence is no longer perfectly flat and straight along its length, where you push the edge of the board up against it - it is slightly worn towards the blade so a long straight edge pushed tight against it will show a very slight tapering gap toward the blade end of the fence. So when the fence is squared up for a large board, a smaller board that only makes contact with the worn section will be tilted slightly off square
@@Alastair_Freebird yes, literally just finished the video you sent me. Great video. Thank you for that. You should put that on UA-cam as well, it’s great info you have there. I’ve also heard that a .002 “toe out” between the blade and the rip fence is good for safety.
Looks very stocked! Looks brilliant. Does this mean you will be machining more of your doors instead of outsourcing to a cnc machinist ? Just being nosey! Haha
Oh yes, once we get the CNC machine we will certainly do all our own shaker doors using that solid panel cut our method (and maybe doors for others too!)
Looking great Alistair 👍 I reckon next year is gonna be a good year for Freebird. The time and money you have invested in the new shop after all the crap we've been through this year is a true testament to your mentality and determination 👏 Matt @bespokedhandmadefurniture
Hi Matt, I hope so! Trying to find and follow you on Instagram under that name but not sure I’m finding you
I think you already follow me mate
👍
Congratulations 👏👏🤣
I like working
I want to work you 😢. I live in Brazil.
A bit far 😄
@@Alastair_Freebird 😭
nice video thanks for sharing. If you are interested I also have some lean ideas on my 'malcolm mcgrath' youtube channel. For example overhead boom in assembly area. Cheers
Hi I’ve subscribed! Can you post a link in the next comment to the relevant video?
@@Alastair_Freebird ok
Woww, an amazing video
Ye, I learnt lots how to set up woodworking workshops from
amusingwoodworking com
Extra Motion, Extra Processing, Unnecessary Transportation = These are redundant. Just do Lean 1 "Use Common Sense", You owe me a coffee.
Do you mean you think there is unnecessary transportation etc in our current plans? Please elaborate, show me where to improve and I will happily buy you a coffee!
@@Alastair_Freebird I don't drink coffee, just a joke. Just saying these lean recommendations are common sense. I used to do general home remodeling but it was too competitive. I switched to historic wood window restoration with linseed oil paint. I now have a niche in the already less competitive window restoration market, have differentiated myself and work mostly at home. I also make wood storm windows and finish them with linseed oil paint. Lean is fine but finding less competitive niches where lean matters less is better.
Apologies if I took this too seriously! Still, for me, learning Lean methodology has been a bit of a revelation. What I previously thought of as ‘waste’ I now see is not that at all, and what I previously thought of as efficient I now realise is often not! For example I used to think it was wasteful to throw away offcuts. I had to learn the hard way that the real waste is the storage space, distracting clutter, and time that those unused bits of wood take up in a workshop when they hang around for years! ‘Lean’ thinking gave me the language and the eyes to see what was already happening in my old workshop and acknowledge it as counter productive. Conversely, where I was spending a lot of time creating systems that were never fully implemented, or not fit for purpose, I’ve been able to understand these as the waste of overprocessing. The considerable time we spent planning the flow of this workshop, and building equipment such as those partitioned carts that saves both labour effort and time is already paying dividends when work is flowing through, but perhaps it’s harder to see when they are just sat there in an sort workshop for the Christmas shut down!
@Richard McKrell
Lean is a modular approach and it is systematic as well. It is a way of thinking and you could just as easily describe it as common sense but it does give you a frame of mind and it also means you can implement it in a business and people can understand it hence why it is easy to implement.
@@bighands69 Yes I know all about 'just in time' it's been around forever.
Do you need to pay a coach to tell you to put your saw and racks near the door and to build some trolleys? This is all just common sense. Sounds like a waste of money to me. 🤣
There’s a little more to it than that 😁 but actually sometimes I do benefit from having a coach simply to help me see the wood from the trees and get my priorities right in the mad rush of day to day work - too many businesses don’t do the obvious because they’re too caught up in day to day fire fighting!