Current Situation (March 2009)

Attached is a spreadsheet with a high level inventory done during Volunteer night on March 10, 2009.
See the spreadsheet with parts notes

The small parts drawers are falling apart, label are falling off, parts are all mixed in, and we have too many of some parts while too few of others.

The current system has served us very well, but it is time to put some work into re-vamping it.

Who is involved? Who has a stake?

Who is impacted by the organization of small parts?

Who will help keep them organized?

Anybody against new organization?

Basic Requirements

Size Approx. Dimensions a Volume Unique Parts b Room for Expansion Total
Small 2.25″×5.875″×1.25″ 16.5 in 3 79 16 95
Medium 5.5″×15.25″×2″ 167.75 in 3 38 7 45
Large Varies Varies 4 6 10

NOTES:
a) Dimensions are: Width x Depth x Height (inches)
b) The parts from “Large” include:

  1. axles
  2. headset bolts
  3. quick release skewers & parts
  4. spokes

What If and Dream Requirements

In addition to replacing the broken and mixed-up bins that we currently have, it would be nice to create a more powerful parts storage system.

General goals for a storage system:

Target Goal

We want sturdy small parts storage with convenient sorting, fast searching, and proper space for everything from common to special use components.

Whats success?

How do we know if we reached our goal? What measurements can we use to validate our solution?

Success Criteria:

  1. Proper Space
  2. Sorting and Searching
  3. Intuitive or Educational
  4. Sturdy
  5. Feasibility

Free-Forms Ideas

Bad ideas: ways the system can fail!

Initial Suggested Bins

A new bin system that is more sturdy and flexible would serve the shop well. A typical system would be of hanging bins. There are many alternatives if we wish to go the commercial route:

Hanging Bins

Other industrial storage solutions from MSC

Bins, but don’t hang them

Hanging the bins may not be the best thing to do. An alternative would be to put the bins onto a shelf. Preferribly, a shelf built to fit the bins in a very space-efficient way such as the one shown below:

Pros and Cons

Hanging
www.globalindustrial.com/p/storage/bins-totes-containers/pick-racks-wall-panels/louvered-wall-panel-without-bins-36x19-blue-2
Pros Cons
Mounting to existing wall/panel Cost is high and requires a sturdy wall
Easy to mix and match bin sizes Bins can break at their hooks
Spacing is predetermined and always nice Hanging requires care and can not be done quickly
Space is devoted to specific bins of specific type
Shelving

Would be DIY, but could be made similar to
www.globalindustrial.com/g/storage/bins-totes-containers/bins-with-shelving/steel-shelving-plastic-shelf-bins

Pros Cons
Low cost Shelf has fixed size
Simple Spacing is not guaranteed
Space can be made multi-purpose Space can get chaotic
Less stress on the bins Not utilizing bin features
Can stack bins if wanted Extra space can introduce clutter
Shelf can be customized

Concerns

Initial Suggested Drawers

Detailed Specification

Storage method

The most promising storage method is to use stacking bins of various sizes that will be placed onto a shelf or multiple shelves.

Bin sizes and Numbers

Estimate based on inventory

First pass look

Very rough estimate based on a high level inventory completed earlier. We have about 15 different options for sizes to choose from from one manufacturer alone.

Size Dimensions Quantity
Small 4-1/8" 4-1/2" 3" 95
Medium 4-1/8" 10-7/8" 4" 45
Large 8-1/4" 10-3/4" 7" 10

Note: dimensions are Width x Depth x Height

Assumed shelf parameters

W, Shelf row width: 48"
t, Shelf thickness: .5"
G_h, Wiggle room height: 1"
G_w, Wiggle width room per bin: .25"

How much height is needed for the small and medium bins?
S = number of small bins = 95
M = number of medium bins = 45

N1, Number of small or medium bins per shelf row
(row width)/(bin width) = 48"/4.125"
Approximately N1=11 bins/row

Required number of rows:
(number of bins)/(bins per row) = (S+M)/N1
130/11
Approximately 12 rows

Required height (Assume 4" bin height":
(Number of rows) * (Bin Height)
H1=12 * 4" = 48"

How much height is needed for the large bins?
L = number of large bins = 10
N2, number of large bins per row
(row width)/(bins width) = 48"/8.125"
Approximately N2 = 5 bins/row

Required number of rows:
(number of bins)/(bins per row) = L/N2
10/5
Approximately 2 rows

Required height:
(Number of rows) * (Bin Height)
H2=2 * 7" = 14"

What is the total height including wiggle room and shelf thickness?

H1+H2+(N1+N2) * (G_w+G_h)
(48+14)+(13)(1.5)=81.5"

Approximately 7 feet high

Modifications to help make the bins fit

We can make modifications to get the height or width smaller in order to fit the bins system into our existing shelf space. Here are some of things we could do: