Layout essentials
The cage should reduce friction, not add it. The faster a tool can be found and returned, the more the system will be respected.
A simple layout beats a complex one. If a new worker can understand the layout in under five minutes, it is a win.
- One main aisle with clear sight lines.
- High-velocity tools within 10 steps of entry.
- Bulk storage separated from daily-use tools.
- Label zones from left to right and top to bottom.
Labeling that lasts
If labels fade or peel, the system dies. Use large fonts, bold colors, and duplication where it matters.
Label zones at eye level and label shelves or bins at hand level. That double label makes returns faster.
- Weather-resistant labels or laminated tags.
- Zone names at eye level + shelf labels below.
- One-letter/number codes for quick reference (A1, B2).
Storage hardware basics
The best layouts use simple hardware that keeps tools visible and easy to access.
Hooks, clear bins, and open shelves are faster than closed cabinets for daily-use tools.
- Open shelves for high-velocity tools.
- Clear bins for consumables.
- Locked bin for high-value or specialty tools.
Minimum tracking list
Track only what matters at first. Use a short list so the team sees quick wins.
- Power tools and kits
- Specialty tools (lasers, cameras, testers)
- Tools that delay work when missing
Weekly maintenance ritual
A quick weekly reset is the difference between order and chaos.
Keep the ritual short and consistent. If it takes more than 20 minutes, simplify it.
- 110-minute zone tidy
- 2Update last-seen for high-value items
- 3Flag missing tools and assign follow-up
What to avoid
Avoid layouts that require a supervisor to explain where things go. The system should be self-explanatory.
Do not over-label or over-categorize. That creates confusion and slows down returns.
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