OSE Shop 2011 Dalton Consultation

=Design feedback from a Production/Floor designer=

Outline extracted from a conversation between David Ihnen (design proposer) and David Dalton of Kansas City, a professional production floor layout contact.


 * Shop Design:
 * likes the roof angles
 * Chlerestory brings lots of light in, that is good
 * Gantry is good
 * Biggest problem: Headspace.
 * low cieling feels claustrophobic, is not so nice to work in.
 * extra cieling space can be used to hang racks and store materials
 * too little overhead space and you can't do anything about it
 * Gantry system needs space for hoist - it would lucky to be able to lift a lifetrac off the ground at its current height of 9 feet at top.
 * Storage space
 * A nearby building - suggest the gantry extends to a shed to the north, where production materials will be stored. Gantry allows easy retrieval without ground level improvements (concrete).
 * Compressed Air.
 * Compressed air is critically important for cleanup, blowing bits out of crevasses better than about anything.
 * Compressed air tools are bulletproof - electric ones wear out quickly,compressed air tools do not.
 * Compressed air tools are powerful and buffered - no matter how slowly compression is generated, maximal power is available at the moment it is needed.
 * Compressed air does not require electricity - either directly off of wind power (good idea!) or steam, or gas engine, or lister - whatever.
 * Take the time to distribute your compressed air around the shop
 * keep your requirement for flexi-hoses short, 4 inner columns good location for them
 * Gantry.
 * Excellent materials handling solution
 * makes moving heavy things, lifting them up, etc far easier - when dealing with heavy things, that hoist can make a world of difference.
 * Transport from storage to production floor is easy and smooth
 * Tiger Stop
 * All About Tigerstops: []
 * Example used model on ebay [] - sold for $4500
 * Any sort of production needs a length-measuring table with adustable stops for efficiency
 * tiger stop style table will accelerate production massively - 30-40% easily.
 * fully automatic tiger stop style table will accelerate parts cutting even more
 * is a single-axis cnc - not difficult to arduino and construct ourselves!
 * consider a double ended table, one end bandsaw, one end mitre saw
 * HIGH USE TOOL - as the most frequently useful tools in the shop, it should be centrally located
 * Can also be equipped with a drill press for automating positioning of materials to be drilled!
 * The Robots.
 * Put robots in range of equipment
 * consider flexibility - hard-mounted robot gets in the way when not being used
 * robots are useful only when actively programmed.
 * board mill->robot->rack->robot->cnc->robot->rack workflow could automatically create wooden parts
 * robot combined with tiger stop type table could automate much workflow of creating metal parts too
 * Table Saw
 * You ABSOLUTELY DO want a table saw if you're doing wood fabrication
 * a large one - or don't bother
 * can double as workbench with blade retracted
 * Dust Collection
 * Install a dust collection system if you're going to be routing and/or cutting much wood. Recycle the chips for fuel, and the fine sawdust is even more useful.
 * use a two stage filtration chamber to separate - easy to build
 * Curtains
 * Put BLACK curtains around the welding areas.
 * Welding flash causes eye damage, even indirectly
 * Welding exposure is bright UV, impacts more than merely the eyes of those around, radiation burns too.