Shadowed Toolboxes and Tool Control Techniques

[AviationTech]

Well, I finally gave into our new company policy of 100% tool control after months of procrastination and making sure I was out for lunch when the auditors showed up, but my boss basically gave me an ultimatum to get my tools shadowed or find another job. The shop did provide the closed cell foam and time needed to shadow and now that it is done I really like the final product. Not something I would have chosen to do on my own, given that we also have to inventory and account for every tool at the end of every shift, but I guess it is good quality practices. I used a base layer of 1/4 inch yellow foam topped by 1/2 inch black foam, so there is no overlooking a missing tool. I tried different techniques throughout the process and certain sheets turned out better than others, but I found using a sharp exacto type knife worked better than anything else I tried. If anyone else has a shadowed box, I'd like to see how it turned out and what you found worked best. This was a first for me.

 

[AviationTech]

More pics

 

[metaldad]

you got paid to do that?
you (obviously) won!
nice job.

 

[maxpower_hd]

I don't do it either since I don't have to comply with FOD criteria.

But it does look like a good idea. I should actually consider it so I don't keep losing tools. There seems to be one tool a week that gets displaced. Either lost because it got left in a truck or misplaced if it got left on the bench or floor.

If something gets left in an aircraft engine cowl then that's a little more serious. LOL

 

[AviationTech]

Yeah, they actually did pay existing employees to do it. New hires are required to have it done before they start from here on out. We were required to utilize our slack time better than we had been in the past, no more sitting on the computer watching YouTube waiting for the plane to block. We were expected to be shadowing tools.

 

[FigureItOut]

That looks fantastic. I'm curious about something, would a missing tool ground every plane you've touched until it's found?

Sent from my SAMSUNG-SGH-I337Z using Tapatalk

 

[AviationTech]

In my experience, if a tool is reported lost on an airplane it does ground the airplane from being released, ultimate authority usually rests with manager if quality assurance if he can prove resources have been exhausted looking for it, he has at his or her discretion to override but I've never seen that happen. I've seen planes grounded for days and floors ripped back up looking for tools. Work stops sometimes and multiple techs can be directed to help in the search

 

[Sloper0204]

I used Kaizen foam for my Pelican 0450. It looks like smashed ***, but it works for now. Going to be adding some neodymium magnets to keep a few things in place when rolling/carrying/transporting. I don't have pictures of all the drawers either.

In use:

Junk drawer hasn't been organized yet:

 

[bcradio]

Very nice job OP. I would love the look for my tools, but I always seem to keep adding and moving stuff around.

 

[Richard Cranium]

I shadowed one drawer in my last box, But keep changing tool to often.

 

[AviationTech]

The pelican cases are a pain, bit definitely necessary in my line of work. I have 2 pelican cases a 1620 and 1510 as well for mobile repair work that they expect shadowed. I was going to take some 1/4 plywood and glue the foam to it, so the pelican has trays of tools that I can lift out and just place on and ground or a table if im lucky enough to have one set up next to the aircraft I working on. I agree you really loose a lot of space, but the tool control systems are becoming industry standard especially on the miliatey contracting and corporate flight department sectors. They have also made us make an inventory sheet of every tool and a description in every drawer, engrave with unique identifier of your choice. That inventory sheet in kept on file with out quality control manager. Needless to say I'm very careful who I loan tools to because if it's misplaced I'm on the hook for it.

 

[Hagatronics]

The easiest way is to go to toolbed.com . I iust had mine delivered and could not be happier. They have a huge database of tool shapes, you just punch in the manufacturer and part number and it presents the shadow for you to locate where you need it in the drawer. The foam arrives laser cut to perfection.

 

[Sloper0204]

I was going to take some 1/4 plywood and glue the foam to it, so the pelican has trays of tools that I can lift out and just place on and ground or a table if im lucky enough to have one set up next to the aircraft I working on.

1510 with shadowed trays for access. The foam is bonded to kydex sheets rather than plywood. It isn't absolutely rigid but it allows for easy removal and replacement.

My application isn't aviation, but oil and gas. If we wind up leaving anything of ours inside processing equipment on a refinery it makes for some... interesting... consequences.

 

[Sloper0204]

The easiest way is to go to toolbed.com . I iust had mine delivered and could not be happier. They have a huge database of tool shapes, you just punch in the manufacturer and part number and it presents the shadow for you to locate where you need it in the drawer. The foam arrives laser cut to perfection.

Thanks for the website, it is exactly what I've been looking for. Had a couple custom foam places quote me close to $1,000 to design and cut high density closed cell foam for my 0450 which is why I wound up cutting my own.

 

[vintage nut]

I'm half tempted to do this just so it forces me always to put things back in exactly the right place....

Sent from my MotoG3 using Tapatalk

 

[ptschram]

The easiest way is to go to toolbed.com . I iust had mine delivered and could not be happier. They have a huge database of tool shapes, you just punch in the manufacturer and part number and it presents the shadow for you to locate where you need it in the drawer. The foam arrives laser cut to perfection.

That is ****!

How much does it really cost? The website kinda skirts around that topic until you register.

How do you keep it clean?

Did they put the Snap-On logo in?

I understand in some countries, Snap-On provides the service, but it's typically in countries where the shop provides the tools.

I spent some time as an A&P apprentice in a shop rebuilding crashes run out of a glorified garage on an alley in a residential area. The guy I worked for could tell if a tool was missing in an instant, having worked out of the same ragged box for 30 years. If I missed picking up a tool, there was HELL to pay until it was found.

That said, he did teach me the wisdom of taking a break about every hour, cleaning up tools, putting things away and going back to it. A practice I try to teach to my employees and customers to this day 35+ years later.

Maybe when I retire I'll go full FOD

 

[AviationTech]

I like the kydex sheets idea alot. One of the techs at the shop went with a similar company to toolbed. They actually sent these special sheets of paper that you lay your tools on and run the supplied ultra violet light over the tools and paper and it makes a perfect outline. Then you package it all up and send the sheets of paper and quipment back. They laser cut the foam to match the templates you supplied to your color, density and thickness specs and mail it back to you. I thought I came out very nice but it cost him around 500-600 US for a pelican 1620

 

[Hagatronics]

The cost depends on the drawer size and whether you want single layer 18mm or double layer 31mm foam. The 13mm has a shadow depth and 5mm base. The 31mm double layer allows more complex shapes as each layer is cut independently.

A 568x398mm drawer costs AUD$60 (USD$45) in single layer or AUD$85 (USD$65) in double layer. The number of cutouts doesn't affect the price. I'd say that's not too much more that the cost of the foam itself and you get a laser cut perfect finish, and don't need to screw around with knives and contact adhesive.

Yes they put the Snap On logo (it's just another shadow from the database). Don't know about other countries but in Australia Snap On use these guys. I was lucky enough to save some shipping costs as they were delivering two pallets full of toolbeds from Germany to Sydney that I could piggy back on.

 

[Sloper0204]

I thought I came out very nice but it cost him around 500-600 US for a pelican 1620

$600 for a 1620 to be cut is pretty reasonable pricing depending on the quality of the foam. My 1510 was somewhere around $400-500, and I sent all my stuff to them to have it designed and cut.

If you don't mind asking your friend what company he went with, I'm trying to find a solution to present to my management for some specialty applications that none of us feel comfortable taking the responsibility for cutting the foam for. I would rather not have a $40,000 piece of equipment entrusted to some foam I might or might not have cut correctly.

 

[LS6 Tommy]

I love the way that looks, but at the very least I'd probably need to triple my storage space to do it...

Tommy

 

[Hagatronics]

I'll put more photo's on the "show us your toolbox" thread, but here are some other shots.

 

[ptschram]

If you don't mind asking your friend what company he went with, I'm trying to find a solution to present to my management for some specialty applications that none of us feel comfortable taking the responsibility for cutting the foam for. I would rather not have a $40,000 piece of equipment entrusted to some foam I might or might not have cut correctly.

I suspect that a company that has expensive pieces of equipment has insurance on said equipment-or a blanket on all equipment.

For $40K, I'd pay the deductible!

And, if it's a critical piece of equipment, there should be a back-up.

 

[Sloper0204]

I suspect that a company that has expensive pieces of equipment has insurance on said equipment-or a blanket on all equipment.

For $40K, I'd pay the deductible!

And, if it's a critical piece of equipment, there should be a back-up.

Insurance on said equipment, sure.
Back-up, sure.

Replacement or back-up available on a time-critical project where we are measuring project delays in hours rather than days or weeks?

I'm not financially responsible for the tools and equipment that are high dollar, but I am responsible for project delays. The $40k piece of equipment I reference is one of many in my trailer, and not the most expensive either. Highest value pelican we run with right now is a 1650 that has an insured value of $120,000. The equipment that sits in it is impact sensitive, freight companies get a bit twitchy shipping that one for us.

 

[AviationTech]

Insurance on said equipment, sure.
Back-up, sure.

Replacement or back-up available on a time-critical project where we are measuring project delays in hours rather than days or weeks?

I'm not financially responsible for the tools and equipment that are high dollar, but I am responsible for project delays. The $40k piece of equipment I reference is one of many in my trailer, and not the most expensive either. Highest value pelican we run with right now is a 1650 that has an insured value of $120,000. The equipment that sits in it is impact sensitive, freight companies get a bit twitchy shipping that one for us.

I just spoke with him and he said the company used was www.foamyourbox.com. all he shadowed was hand tools but I thought I was nice that your tools never left your possession. Kind of an added plus in my eyes

 

[Sloper0204]

I just spoke with him and he said the company used was www.foamyourbox.com. all he shadowed was hand tools but I thought I was nice that your tools never left your possession. Kind of an added plus in my eyes

Awesome, than you

I'm going to give them a call Monday. We have lots of UV lights that we use for work, might be able to do it without needing their light.