Shop Design 101 Make the Most of Every Square Foot By Traci Matt Associate Editor In 1991, Dick Vensel of Vensel Enterprises wrote an eye-opening article for the Exchange illustrating how just a few extra steps a year in your shop can cost thousands of dollars—and this was at the rate of “$25 per hour, per man.” He included the calculation that even nine minutes a day of time lost to inefficiency translated into a whole week a year. Now do the math in today’s dollars. This month we are revisiting the issue of efficient layout and updating other aspects of shop design for the 21st century. In the years since Vensel’s orig- inal piece, he said rebuilding has also become more specialized and even “more sophisticated.” His °91 article included examples of “work cells” with ideas for per- forming specific jobs with the least amount of physical movement or steps. These principles apply even to “sophisticated” rebuilding. “To make this work for you, all that may be needed is to reposition what you have now,” said Vensel. “Always keep in mind that wasted steps should be elimi- nated to increase productivity and profit. The best time to clean up and sort things out is when you are rearranging for less movement and better efficiency.” So whether you decide to add a fresh coat of paint to an existing shop, or you are moving to a new space and looking for ideas from the ground up, here is some advice from the experts. Begin with a plan. Whether you use graph paper and scale-sized cardboard cutouts, purchase blueprint software, or use an online design tool, decide where to place fixtures and equipment before you start moving anything. Don’t forget details such as where material handling carts and waste and scrap containers will end up. As an added bonus, if you are doing an extensive remodel or new construction, this plan will show you exactly where to put electrical outlets, wiring, and air con- duits. Be sure to check local building codes and secure proper permits. Visit other shops and use your net- work of rebuilders for ideas before you even pick up a hammer. Look Through Your Customers’ Eyes According to Mohammad Samii, industry educator and owner of Sammy’s Auto Electric in Champaign, Ill, your shop’s professional appearance will translate directly into dollars. “Signage and the outside appearance of your business are of the utmost importance for bringing in customers,” said Samii. “Clean and nicely arranged waiting room, spotless bathrooms and general all around cleanliness goes a long way for conveying a professional attitude and also being able to charge top prices for your work.” Take an impartial friend on a tour of your sales area and ask for honest feed- back. Do you need to get your old sign and faded parking stall stripes re-painted? Are your hours clearly posted? Do you need to purchase (and use) a large, lighted “Open” sign? Make your customer counter area as interesting and well-lit as possible. Display items like chrome or powder- coated alternators and starters. Hang photos and framed certifications on the Ih Sena Sammy’s Auto Electric touts a drive-through bay—the ultimate in convenience with tow-in customers. Work Cells for Small Shops Sample Location: Component Subassembly Testing, Armature Courtesy Richard Vensel and Rotor Turning, Final Assembly, Testing and Painting Sample Location: Teardown H. Component Testing, Lathe, Arbor and Cleaning Press and Tooling; storage for scrap H | K A. Teardown Bench with Power parts under the bench and Hand Tools |. Distance between benches | B. Bushing Puller, Arbor Press, B A B approximately three feet Pulley and Bearing Pullers; any J. Final Assembly Bench J | L other necessary equipment G K. Paint Booth C. Degreaser, Shaker, Tumbler L. Final Test 0 or Cleaning Tank Cc DIE IF D. Steel Shot Blaster Sample Bench Usage N E. Sandblast Cabinet M. Scrap Parts Storage F. Small Parts Sandblaster N. Hand and Power Tools G. Workspace between teardown bench and cleaning O. Most Popular Parts Storage M equipment approximately three feet.