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Tool storage and accountability

Kscardsfan

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I’ve been trying to clean up and organize our shop at the park and one of the ongoing issues I’m dealing with is tools migrating into trucks and never returning to their spot. Are there any good ways to keep tools where they’re supposed to be? And are there good ways to be able to check at a glance if something is missing or out of place? I’m upgrading the shop tool boxes to something out of the modern era and getting peg style socket organizers to improve visibility and accountability for inventorying them. And I’ve been looking at the Williams Hi Vis combo wrenches as a way to keep them in the box and make them easy to spot in a truck bed or passenger seat. But I’m open to all ideas. My end goal is to be able to randomly spot check our inventory and then run down the usual suspect regarding why the tool(s) are missing/out of place and prevent this from happening anymore. It took me about it 5-7 minutes to find a socket and appropriate combo to change a battery in one of our tractors the other day and I was livid by the end of it. It’s no wonder our maintenance shop is so inefficient based on how long it takes to get the right tools together to do a simple task like that.
 
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Jsf721

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May not work in a busy shop but if I ever loan out a tool (rarely happens), I take a picture of the person I loaned it to and put it in a special album on my phone. When I get it back i delete it. Helps me remember and also they cannot say, I never gave it to them. I tell them make sure I delete your evidence pic when you hand it back :).
 

FMB4

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I quit loaning tools to all but the lead mechanic (shop owner's son) back in the late '80s. Did so after another mechanic borrowed a seal removal tool that he needed to take home with him. Days later I asked him for the tool. He replied that "he gave it back to me" while his buddy (a kid cashier at the shop) said "ya, I saw him give you that tool back". However he did not give it back to me.
 
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will335i

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We had this problem with some of our crews when I worked in the oil field. If you are the manager or these tools are your responsibility then the first thing you need to do is counsel all the crew members that the job is not done until the tools are cleaned and returned to the proper place. This can be done as a group or one on one and needs to be documented that each employee received this counseling.

Next is inventorying. There are a number of ways to "shadow box" toolboxes. You can go as simple as paint outlines or go foam like the aviation industry does. Once you have all the drawers laid out, I would take pictures of each drawer that would be combined with a written list of each tool and quantity. These can be laminated and attached to or stored in the toolbox. Unless have different toolboxes for different use cases I would make each toolbox exactly the same.

The next issue is tracking the company owned tools. Hi vis paint is great option. If you find that it is getting scrapped off you can go more extreme and put serial numbers on each individual tool. This can be very tedious if you are doing by hand. All the toolboxes need locks on them and they are inventoried and locked at the end of each day. Either you or another responsible person manages the keys. Keys are signed out at the beginning of each day so you have a log of who had access to the tools if you need to track down a missing item.

Finally actions. In my opinion there cannot just be consequences there needs to be some positive reinforcement. If they show they are able to follow this new plan then show you are willing to buy better quality tools or if they are saying they need a tool they don't have to do a job get it for them. Or you mentioned tools keep ending up on trucks, so make some toolboxes for the trucks that follow the same guide as the shop tools. On the consequence side, as long as you have the expectations documented, you have number of options. The person/crew that signed out the keys has to pay for any missing items at the end of the day, they get the **** jobs for a week, they get the hand-me-down tools, they have to wash all the trucks and clean the shop, the list goes on up to and including termination for repeat offenders or depending on the value of the items.

Other things to consider, moving from shop owned tools to employee owned tools, if it is theirs they are more likely to take care of it and this allows them to personalize the tools to them and take some ownership of the work. The employees would need to be compensated if they are suppling the tools through hire pay or a tool allowance though.

If all the tool boxes have the same tools then I would use a different color or serial number sequence for each box so that crew A can't swipe from crew B's box if they are missing something.
 

aggiegrads

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5S is great for this, but here is what undermines every “first” lean implementation: accountability. There are several steps, but the first is to standardize the tool board or box so that you know what goes on the board and what is unneeded. That is the easy part. You also need a system where you can identify an out of control condition (i.e. a missing tool) in a few seconds. With a good shadow board or tool tray, one should be able to detect the missing 10mm socket in less than 10 seconds standing 10 feet away.

Here is what we did in my workplace and it works very well. We rarely lose tools, which is good because we use expensive tools. Think multiple digital torque tools, custom made torque wrenches, and high quality bits and sockets - everything is American, Ja-anesthesia, or German - you get the idea.

After we finalized the layout of the tool boards, every one has a card on it - green on one side and red on the other. You can use any visual indicator here. I helped a friend set up his machine shop and we used red and green solo cups. At the end of the shift, everyone puts the tools back on the board. We allow work to stop 15-20 minutes before the end of the shift so that everyone has time to clean up and organize. When everyone is done, the supervisor walks around and inspects every tool board. If nothing is missing, he or she makes sure that the card is showing green. This takes them about one minute for 10-12 tool boards. If a tool is missing, everyone looks for it until it is found. They look inside equipment, under equipment, etc. until the tool is found. Nobody is dismissed until everything is found. The incoming shift supervisor takes a quick look to make sure that all of the boards are “green” any may make the choice to “audit” the boards themselves. When they say that everything is good, then the employees are dismissed.

At lunch break, everyone turns their tool boards to “red” so that they know that the board has not been checked for the day.

This really works. Everyone is diligent about checking the boards because they don’t want to be blamed for a lost tool, but more importantly, they want to start the day with a full set of tools that makes their work more efficient and less frustrating.

I suggest that you implement this accountability system with something less critical, like cleaning the shop. It will take time to implement and get everyone in the habit, but everyone will be happier for it.
 
OP
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Kscardsfan

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Having sets in both places. If people are taking them to their trucks, it means they need them there.
No our maintenance guy is a hoarder and lazy. He has probably 4-5 shovels but has said he won’t dig up a leaking water line. His other classic is “my truck is so full of supplies so that way I don’t have to go to town to get anything” and he regularly makes 2-3 trips into town a day for supplies. It’s a legacy of previous indifference from supervisors and managers that ends with me and my manager. He’s the same guy who tried to weld up a cracked 3/4” impact socket and created this abortion instead of asking to buy a 1/2”-3/8” impact adapter. The number of chrome sockets that are wallowed out from being impacted in this shop is staggering.
 

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Odd-job

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No our maintenance guy is a hoarder and lazy. He has probably 4-5 shovels but has said he won’t dig up a leaking water line. His other classic is “my truck is so full of supplies so that way I don’t have to go to town to get anything” and he regularly makes 2-3 trips into town a day for supplies. It’s a legacy of previous indifference from supervisors and managers that ends with me and my manager. He’s the same guy who tried to weld up a cracked 3/4” impact socket and created this abortion instead of asking to buy a 1/2”-3/8” impact adapter. The number of chrome sockets that are wallowed out from being impacted in this shop is staggering.
I'm not sure if I should be impressed or shocked in horror on that monstrosity. Would give the maintenance guy some kudos on the creativity in combining a 1/2 socket with a 3/8 pipe socket. That being said it would defeat the purpose on a stubby impact...

Time for some armchair maintenance shop/truck quarterbacking here...

Is there anyway to bifurcate the tool sharing between the maintenance shop and the maintenance trucks? Sounds like the same guy has to work in both which is contributing to the problem so not sure if that is possible. Not sure how many maintenance guys there are, but can imagine you can track the spending on consumables and tools somehow to hopefully encourage less hoarding and lost tools on a relative basis and follow up to extent you quantify the issue. Definitely an easier argument quantifying things rather than relying on purely anecdotal evidence when it comes to HR matters. Did you confirm he actually has 4-5 shovels?!? Can you see and track his spend on his supply runs where he probably gets to buy new tools (and 5 more shovels) along with supplies? Hoping you can't tell my day job is accounting...

Also doesn't sound like anyone deserves chromies. Cheap, spray painted pink, impact sockets sound like a better fit for the prevailing working habits...
 
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Kscardsfan

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I'm not sure if I should be impressed or shocked in horror on that monstrosity. Would give the maintenance guy some kudos on the creativity in combining a 1/2 socket with a 3/8 pipe socket. That being said it would defeat the purpose on a stubby impact...

Time for some armchair maintenance shop/truck quarterbacking here...

Is there anyway to bifurcate the tool sharing between the maintenance shop and the maintenance trucks? Sounds like the same guy has to work in both which is contributing to the problem so not sure if that is possible. Not sure how many maintenance guys there are, but can imagine you can track the spending on consumables and tools somehow to hopefully encourage less hoarding and lost tools on a relative basis and follow up to extent you quantify the issue. Definitely an easier argument quantifying things rather than relying on purely anecdotal evidence when it comes to HR matters. Did you confirm he actually has 4-5 shovels?!? Can you see and track his spend on his supply runs where he probably gets to buy new tools (and 5 more shovels) along with supplies? Hoping you can't tell my day job is accounting...

Also doesn't sound like anyone deserves chromies. Cheap, spray painted pink, impact sockets sound like a better fit for the prevailing working habits...
Yes, I’ve actually pulled 3-5 shovels of various descriptions out of the bed of his truck. And the big issue with this guy is we have sets of tools ready to take out on calls, he just can’t find them or he doesn’t care to look for them so he takes another one out of the shop for that specific project. I’ve found multiples of different combo wrenches and at least two socket sets in his truck looking for stuff before. I know there’s at least 3 different DeWalt impacts/drills in a 5 gallon bucket behind the seat. Or there were, I took them all back into the shop and put them away for the next time. Like I said, it’s a long running combination of indifference and fear of confrontation that’s culminated in this disaster zone of a shop and truck. I’ve attached some crappy pictures of his truck I remembered I had on my phone. It’s legitimately a safety hazard in the cab should he ever be in a wreck or rear ended. All the BS he’s accumulated across the backseat would decapitate someone. One last humorous or horrifying story, depending on your point of view: Him and the previous maintenance manager had a call about a leaking or clogged toilet in one of our bathhouses. Since they’re a commercial setting the plumbing for these toilets is in the walls to keep people from messing with it. They’re accessible through a chase or a panel depending on the layout. These two decided since they couldn’t access it from a chase/hallway that they needed to cut open the masonry/concrete wall with a hot saw to get to the lines and bolts etc. My manager caught them trying to get the hotsaw to crank in the shop and they told him what they were going to do with it. My manager then took away the saw and drove them down there and showed them how to take the panel off the wall and do the required work. It’s a trip out there sometimes.
 

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will335i

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Sounds like it is long past time to have a performance review with said employee. Clearly layout all the expectations and what can happen should they not meet these expectations. The employee should sign that they received this counseling. It would be good that they have some buy-in, understand and agree with the expectations and understands the why. Then start documenting all deficiencies. A paper trail is an absolute must.

Hopefully the employee turns it around but from the sounds of it they were allowed to carry on as they pleased for far to long and may not care to change. The paper trail will allow you do what is needed should they not improve. This is a customer facing employee if they are going to sites and needs to be a better representative of the company.

Go ahead and start writing up a job req for the replacement and make sure you have HRs buy-in too.
 

mbdslpwr

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It ain't about the tools. It's about the people.

Glad you got livid enough to post here. That's good.

It appears you have a leadership challenge and an opportunity to excel. At least that's what your statements suggest - previous leadership allowed indiscipline, for which one person seems to have taken full advantage and you get the pleasure of managing.

In terms of tool accountability, set whatever system makes sense for your conditions. Aggiegrads has a really good answer and odd-job's thoughts on possibly splitting shop and truck sets make sense. That's the easy part.

What makes it all work, though, will be you, Mr. In-Charge. It's a people problem at heart.

1. Derive your system and the new rules from the objectives of employee safety, efficiency, and accountability. Doing so allows you to fall back on good rationale for the changes. This is a strong "why we're doing this thing."

2. Once set up, teach folks the new rules. Make those rules clear and logical. Make sure you clearly communicate the new rules.

3. Take opportunities - both when people do wrong and, more importantly, when they do right, to remind your team why you've put the system in place (see #1 above). Examples include:
3.a. "I want everyone to easily locate their tools so we can all focus on the work at hand."
3.b. "I want to quit losing tools, because it costs time and money I could otherwise give to you all via nice upgrades." (if such is the case),
3.c. "Your tomorrow-morning selves will thank your yesterday-afternoon selves for putting things where they belong."

4. Counsel immediately when the new rules aren't met. Reward employees who reinforce the new rules (this is more effective when you know what's important to them - a good note in the personnel file, public comment, tool upgrade, etc.).
4.a. When counseling, rapidly ID if the issue is an employee lack of understanding or unwillingness to change. If the former, give the benefit of the doubt and offer up a retraining with an observation and follow-up after a period of time.
4.b. If it's a lack of willingness or a case of indiscipline, record as such and give an opportunity to make a change or tell them to pack their bags. Revisit soonest after an opportunity to demonstrate change in behavior.

5. Put things in writing.

Team success demands everyone pull their weight. Don't tolerate laziness now just because a past manager did. People joke about leadership challenges but you have a great opportunity to make a positive impact on your team.

Wish I knew more about this 5S stuff, though. Maybe someday.
 

mogandave

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Running around red-faced once or twice a week will do nothing but exasperate the problem.

Starting a 5S program and putting together shadow-boards and whatnot is pretty easy. Management's part is talking, perhaps wearing jeans for a day or two or three, and spending a little money. Management likes this, and they are mostly good at this.

Maintaining a 5S program and shadow-boards and whatnot is pretty easy also. Management's part is managing. Management does not like this and they are mostly not good at this.

As hard as it is to get good maintenance guys, it's even harder to get good managers.

If you're a manager and you want to get rid of the guy, getting rid of him should be your focus.

If you're an manager and you do not want to get rid of the guy, making his job easier should be your focus.
 

CGarage

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Some really good advice here in this thread-both management wise and in terms of tool accountability.

I would empty his truck out for him and by this I mean dumping the contents of the truck out onto the ground. Respectfully.

It is long past time for a “New Start”.

I would proceed to develop a checklist of what is needed for typical jobs and quantities that need to be carried. And have him account for his ****.

The items that there are multiples of that he was carrying then go back into the main shop so other employees can have access -equally- to those items.

Just because he can’t get his **** together does not entitle him to unfair and unequal access to tools and supplies due to his lack of personal accountability.

A lack of personal accountability and tool accountability on his end should not result in such a negative impact on others.
 
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Ton ton

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No our maintenance guy is a hoarder and lazy. He has probably 4-5 shovels but has said he won’t dig up a leaking water line. His other classic is “my truck is so full of supplies so that way I don’t have to go to town to get anything” and he regularly makes 2-3 trips into town a day for supplies. It’s a legacy of previous indifference from supervisors and managers that ends with me and my manager. He’s the same guy who tried to weld up a cracked 3/4” impact socket and created this abortion instead of asking to buy a 1/2”-3/8” impact adapter. The number of chrome sockets that are wallowed out from being impacted in this shop is staggering.
I like the impact adapter. LOL.
 

nadogail

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Having been a Manager, I felt my job was to

(1) Have the Vision of what I wanted done. Often the Vision was not my own until my manager made it clear to me.

(2) Communicate the Vision to those who will be carrying out the Vision, and make sure they have the training, tools, materials and Working Conditions to accomplish the Vision.

(3) Monitor their progress and provide both Positive and Negative Feedback as they work to accomplish the Vision. Recognize accomplishments as Commendable Progress and softly address negative issues.

(4) Allow "Ownership" of good work. I remember when Professional Drivers had Badges on "their" Trucks that told the world how many Accident Free Miles they had driven. The carpet cleaning company I use assigns their new trucks to their most experienced and productive employees and the employees name is lettered on the doors of "His Truck". he employees wear company provided and laundered uniforms. Every Workday begins with stretching and "Personnel Inspection". The Inspection takes only a few minutes and makes sure the employees realize that there appearance meets the Company Standard and presents a Good Image to the public. The stretching has been proven to reduce Workers Compensation Insurance Injury claims which saves the company money and reduces employee turnover.Better Drivers got all the New Trucks, the worst trucks went to the drivers who deserved them.

(5) Create and maintain a system of "Tool Control & Accountability" One manufacturing plant allowed operators only the tools they were required to operate and clean their machines. Those tools were on a "Shadow Board" that plainly showed what tools were not in place. At Shift Change any missing tools were highlighted buy a Yellow and Black silhouette.

(6) Provide Public Recognition for meeting published Goals. A few cheap Pizzas on the last Payday of the month becomes affordable with the savings and production increases.

(7) Continue to provide recognition for successful innovation and have an open door for suggestions from the floor; sometimes the best ideas come from unexpected sources.
 

Odd-job

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Great thread, but playing devils advocate here... So I get he's got a messy truck, loses tools, creates creative tools, and one time didn't know how to fix the toilet. I think this is somewhat correctable in that I have seen far worse (he's not stealing, doing drugs/drinking on the job, etc.). How's other aspects of him as an employee? Does he show up to work? Does he get along with fellow employees? Does he mostly get his assigned job tasks done? I didn't hear a manager delivering him feedback to improve upon yet in all of this either which could be a management problem. Anyways just some things to think about it and also lastly want to point out its hard to find good employees in this great resignation age.

Edit: good luck!
 

redwrench60

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Well he’s a state park maintenance guy, so he’s a plumber, mechanic, appliance repairman, equipment operator, electrician, and carpenter depending on the day.
Any real tradesman has their own tools. Doesn’t matter if it’s a plumber, electrician, HVAC, mechanic, body man, millwright or rod buster. They own and maintain their own personalized tool set. It shows they are serious and invested in their trade. The shop provides equipment, job specific specialty tools and shop supplies. If you have to provide a ratchet or a pair of Channellocks then there’s a problem.
 

ecotec

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Any real tradesman has their own tools. Doesn’t matter if it’s a plumber, electrician, HVAC, mechanic, body man, millwright or rod buster. They own and maintain their own personalized tool set. It shows they are serious and invested in their trade. The shop provides equipment, job specific specialty tools and shop supplies. If you have to provide a ratchet or a pair of Channellocks then there’s a problem.
We do not know how any of that part of it works.

I am an electrician. My contact clearly-ish defines what tools that I am to provide, and what the contractor is to supply. It also clearly defines what my tools are insured for.

So, if I need tools beyond my tool list, I have to grab those from a company tool gang box. Every day I am expected to borrow what I need, use it, and return it in good working condition. If a given tool is not in good working condition, I am expected to tell my foreman what is wrong.
 
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Uncle murph

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I’ve been trying to clean up and organize our shop at the park and one of the ongoing issues I’m dealing with is tools migrating into trucks and never returning to their spot. Are there any good ways to keep tools where they’re supposed to be? And are there good ways to be able to check at a glance if something is missing or out of place? I’m upgrading the shop tool boxes to something out of the modern era and getting peg style socket organizers to improve visibility and accountability for inventorying them. And I’ve been looking at the Williams Hi Vis combo wrenches as a way to keep them in the box and make them easy to spot in a truck bed or passenger seat. But I’m open to all ideas. My end goal is to be able to randomly spot check our inventory and then run down the usual suspect regarding why the tool(s) are missing/out of place and prevent this from happening anymore. It took me about it 5-7 minutes to find a socket and appropriate combo to change a battery in one of our tractors the other day and I was livid by the end of it. It’s no wonder our maintenance shop is so inefficient based on how long it takes to get the right tools together to do a simple task like that.
On the other hand.....I can’t tell you how many times I’ve been on a job where a crew shows up without a level,shovel,hammer or some other piece of basic yet essential equipment and 3-4 guys stand around while someone goes to retrieve what should have been standard issue on every truck.Shop tools should never leave the shop and every truck should be equipped with the tools required for whatever the task at hand is ,with someone on every truck being responsible for ensuring that is the case.
 

2ndGearRubber

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Great thread, but playing devils advocate here... So I get he's got a messy truck, loses tools, creates creative tools, and one time didn't know how to fix the toilet. I think this is somewhat correctable in that I have seen far worse (he's not stealing, doing drugs/drinking on the job, etc.). How's other aspects of him as an employee? Does he show up to work? Does he get along with fellow employees? Does he mostly get his assigned job tasks done? I didn't hear a manager delivering him feedback to improve upon yet in all of this either which could be a management problem. Anyways just some things to think about it and also lastly want to point out its hard to find good employees in this great resignation age.

Edit: good luck!

He sounds to me like a common archatype at many businesses. Hes a PITA who accomplishes little, but management has bigger fish to fry so they let him run awry. Hes been easier just to ignore, kicking the can down the road, and now OP gets to deal with the dumb dumb who should have been given the boot years ago. It's a massive pain because these people think they're critical to the operation but are really just a reliable body to fill out a schedule with.

Any real tradesman has their own tools. Doesn’t matter if it’s a plumber, electrician, HVAC, mechanic, body man, millwright or rod buster. They own and maintain their own personalized tool set. It shows they are serious and invested in their trade. The shop provides equipment, job specific specialty tools and shop supplies. If you have to provide a ratchet or a pair of Channellocks then there’s a problem.

If ONE more goober asks me to borrow a basic tool I'm gonna lose my mind. LOL.

NO is the answer by the way. Dont want to work in the Pittsburgh winter? Buy your own jump pack then, you ain't touching mine.
 

lardy1

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Inheriting that mess is not an enviable position to be in. Been there and done that myself. Inheriting employees attitudes, habits, skills, personality.....on and on. I NEVER want to manage personnel in any way shape or form.

We don't know all the specifics and it begins to crowd in on the labor/management blame game from many. I believe tool agreements need to be part of the employment agreement. Who provides what and contingencies for the unexpected. Most people take care of their own **** way better than they'll take care of their employers. Monetary tool allotments can work for both parties if thought out for the specific business and then managed.

But to have to start where the OP is now......Ugghh.
 

ecotec

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Also... this is America. A company tool is the financial responsibility of the company. If a company tool is broken, misplaced, lost, stolen borrowed by another crew and not returned (this happens a lot), this is the company’s job to deal with.

Most people are just there to get their work done in a journeyman like manner.
 
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ecotec

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Tools and their storage,distribution aren't the problem, its time to start the process of replacing the humans.You've heard the saying about one bad apple ??????
This is the ideal. If you can increase the calmness and efficiency of a crew, by getting rid of or replacing one guy, you should do it. If it is the foreman can’t resolve the situation, that crew needs a different foreman.
 

bobg03

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It’s amazing isn’t it? It has a dedicated spot on the shelf in my office now.
I worked for an industrial fire dept in a pharma manufacturing facility for 25 years, we had a wall with shelves too. We called it the 'Wall of Shame"

I can't see this employer making someone buy their own tools, when you are working at a facility such as a park or a manufacturing facility the company should be buying them.

But the employees need to be accountable in some way, shape or form for these tools...
 
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