Tool management to improve productivity

Ever notice press operators searching for tools during setup or operation? Walking from the unwind section to the rewind section to grab a roll of tape, or moving from one station to another to find a wrench? Rummaging through their own, disorganized toolbox for a hex key or tape measure? Walking over to a colleague to borrow a utility knife? Or damaging a screw or bolt with a worn or mismatched tool?

This “loose” approach to tool management often leads to lower productivity and heightened frustration—but it doesn’t have to be this way. The good news? Tool organization is a quick and impactful improvement.

A "Tighter" Approach to Tool Management
For tools used during press setup and operation, I recommend identifying each task that requires a tool, determining where on the press each tool will be used, and selecting the best type and quality tool for each job. I conduct this process with input from all operators and assistants, while also drawing on my experience with tools and pressroom needs.

Starting at the unwind section, I collaborate with each team member to determine the tools they need at each point. This might mean affixing a tape dispenser to the unwind frame, setting a razor knife in a secured tray, attaching a hex key with a magnet, or hanging a combination wrench from the side of the press in a dedicated holder. We continue this process through every section, from unwind to rewind, following the web, specifying which tools belong where and how they should be stored.

Rule of thumb: The operator should be able to reach each tool from where it is used, even if that means placing identical tools in multiple locations. For example, on one 10-color in-line press, operators preferred using scissors to cut the web. We strategically placed scissors throughout the press—one shared at every two stations, one at the die stations, one at the unwind, and one at the rewind. Using similar logic for each tool and task made a dramatic difference in efficiency. The operators and I were pleased with the results—convenience and improved productivity.

This setup also allows for easy access and weekly audits to ensure tools are accounted for and in good condition.

The Impact of Organized Tool Management
With tools consistently accessible and well-maintained, operators have what they need where they need it, leading to a smoother workflow, less downtime, and less frustration. This approach enables operators to focus on what matters most: producing high-quality print efficiently.

If this seems unconventional, or excessive, I understand. But the modest investment is quickly offset by increased productivity and opportunity.

Happy printing!

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