1. Case Overview
This case focuses on the optimization of tool moving and material handling operations at Hefei Changji Tool Manufacturing Workshop. The factory is mainly engaged in the processing and production of hardware tools, precision tool fixtures and mechanical accessory parts. In the original workshop operation, tool handling, finished product transfer and raw material transportation mainly relied on manual carrying and simple auxiliary trolleys. The traditional moving mode had prominent problems such as scattered tool placement, low moving efficiency, easy tool damage and messy on-site management, which restricted workshop production rhythm and standardized management level. Aiming at the above pain points, Hefei Changji Workshop carried out systematic optimization of tool moving work, including configuring special handling tools, standardizing moving procedures and implementing staff standardized training. The optimization realizes standardized, efficient and loss-free tool moving management, effectively improves workshop operation efficiency and site management quality, and forms a set of mature tool moving management schemes suitable for hardware tool processing workshops.
2. Pre-optimization Problems
2.1 Low Tool Moving Efficiency and Production Congestion
Before optimization, the transfer of workshop cutting tools, measuring fixtures, semi-finished hardware tools and finished products completely depended on manual handling. Multiple back-and-forth moving was required for daily tool turnover and station replacement, consuming a large amount of working time of operators. There was no fixed moving route and unified scheduling mechanism, resulting in random tool transportation and serious personnel cross-operation. Irregular moving often caused tool accumulation at processing stations, delayed tool supply and affected the continuity of processing procedures, forming a key factor restricting workshop production efficiency.
2.2 High Tool Damage Rate and Hidden Safety Dangers
Hardware tools and precision fixtures have high requirements for handling stability, but manual moving lacks protective measures. Sharp tools were prone to collision, friction and drop damage during transportation, resulting in tool edge wear, precision deviation and increased scrap rate. In addition, disorderly tool stacking and random moving occupied workshop operation passages, easily causing staff tripping and tool extrusion injuries. Due to non-standard moving operations, the workshop had frequent minor tool damage and on-site safety hazards for a long time.
2.3 Chaotic Management and Difficult Traceability
The workshop lacked unified tool moving specifications and management standards. Tools of different specifications and uses were mixed during moving and placement, resulting in chaotic tool classification and difficult inventory counting. There was no complete moving record, making it impossible to track the circulation status of key precision tools, which easily caused tool loss, misplacement and repeated procurement. The irregular moving mode also increased the difficulty of workshop 5S management and restricted the standardized construction of the production site.
3. Optimization Implementation Scheme（优化实施方案）
3.1 Equip Specialized Tool Moving Auxiliary Equipment
According to the types, volume, precision level and weight of Hefei Changji’s workshop tools, targeted moving equipment was configured to replace pure manual handling. Classified anti-collision tool trolleys and layered storage transfer vehicles are used for precision fixtures and small hardware tools to avoid friction and collision damage. Heavy-duty flat trolleys are equipped for batch finished tool products and large tooling parts to improve moving load capacity and efficiency. All moving equipment is uniformly numbered and managed, with regular cleaning and maintenance to ensure stable use and meet the daily tool turnover demands of the workshop.
3.2 Standardize Whole-Process Tool Moving Procedures
The workshop formulated and issued the Hefei Changji Workshop Tool Moving Management Specification, clarifying unified standards for tool classification moving, route planning, station delivery and centralized storage. Fixed special moving channels are divided to separate tool moving routes from processing and operation areas, avoiding cross-operation interference. A whole-process management mechanism of "tool picking, classified moving, accurate delivery and site sorting" is established. Meanwhile, a moving registration system is implemented to record tool specifications, moving quantity, operators and time, realizing traceable tool circulation management.
3.3 Conduct Standardized Operation Training and Assessment
The workshop organized special training for all front-line operators and administrators, focusing on standardized tool moving methods, precision tool protection essentials, safe moving specifications and on-site standard management requirements. Special personnel conduct on-site demonstration of classified moving and protective placement operations, correct irregular manual carrying behaviors. A post assessment system is implemented; only employees who pass the assessment can independently complete tool moving work. Regular daily inspection and weekly standardized rectification are carried out to consolidate standardized moving awareness.
4. Implementation Effect
4.1 Significant Improvement in Moving and Production Efficiency
After the optimization of tool moving management, manual invalid moving operations are reduced by 85%, and the overall tool turnover efficiency is increased by 55%. The problems of delayed tool supply and station congestion are completely solved, ensuring continuous and stable processing procedures. The workshop’s daily tool scheduling and turnover speed are greatly improved, effectively matching the factory’s daily production rhythm and raising the overall production operational efficiency.
4.2 Effective Reduction of Tool Damage and Safety Risks
Classified protective moving and standardized operation completely avoid tool collision, friction and drop damage. The workshop precision tool damage rate is reduced by 40%, and the tool service life is significantly prolonged. Standardized moving routes and orderly placement eliminate passage blockage and on-site injury risks. The workshop has achieved zero tool moving safety accidents since the optimization, and the on-site safety management level is comprehensively improved.
4.3 Realize Standardized and Refined On-site Management
The standardized tool moving mode realizes classified transportation and fixed-point storage of all tools, thoroughly solving the problems of mixed placement, misplacement and loss. The tool moving registration and traceability system facilitates real-time inventory checking and tool scheduling, reducing tool loss and repeated procurement costs. The workshop’s 5S on-site management level is significantly upgraded, realizing refined and standardized tool operation management.
5. Case Summary
Tool moving is a basic and important auxiliary link in the daily production of Hefei Changji tool workshop, which directly affects production efficiency, tool service life and on-site standardized management. The traditional pure manual random moving mode has many defects and cannot adapt to the refined production management requirements of modern tool processing. Through the configuration of professional moving equipment, standardized operation procedures and standardized staff training, the workshop has completed the comprehensive optimization of tool moving work.
The optimization effectively improves tool turnover efficiency, reduces tool damage and potential safety hazards, realizes traceable and standardized tool management, and optimizes the workshop production environment. This set of moving management schemes is highly practical and can provide effective reference for standardized tool handling and site management of similar hardware tool manufacturing enterprises.
zcmx@xtczmx.com 
+86 15833656013 