Workshop layout and the minutes lost walking.

Organise it around how work flows

Workshop layout often depends on when equipment was installed, not how jobs actually flow.

A vehicle arrives, is assessed, worked on, needs parts, tested, and leaves. Each step has a location, and the distance between them is unbilled time.

Mapping a typical job's path often uncovers crossings that can be eliminated by relocating inexpensive items. Layout improvements are often free yet yield high returns.

Keep frequently used items close

The rule is simple but often ignored: distance should be based on frequency of use, not size or tidiness.

• Tools used multiple times per job should be at the bay, not across the floor on a wall.
• Daily consumables should be at waist height near where they're used.
• Weekly items can be stored further away without issue.
• Monthly items can be stored out of the way.
• Rarely used equipment shouldn't take up prime space, but it often does.

Ironically, the tidiest workshop isn't always the most efficient, as tidiness is based on category while efficiency is based on frequency.

Bay depth, spacing and the door

Workshop layout has physical limits that should be acknowledged before any expenditure.

A bay needs sufficient length to open a bonnet on a ramp, width for two doors and a person, and clearance to remove a wheel without manoeuvring around another vehicle. Cramming in an extra bay where it won't fit delays every job instead of increasing capacity.

The door and access are as crucial as the bays. If getting a car in means moving two others, every vehicle loses time, often due to parking policy rather than structural issues.

Allocate space for parts and waste

Two items build up in every workshop and both end up on the floor without designated spots.

Parts for scheduled jobs need a designated spot linked to the job, not a mixed shelf, as searching for a part from Tuesday is a frequent hidden time cost. Old parts and waste require a route out that avoids the working area.

If these aren't planned for, they take over the workspace, making the workshop feel smaller without anyone realising it.

Light, air and flooring

These may seem like comfort features, but they are vital for productivity.

Bad lighting slows diagnosis and increases errors, yet it's one of the cheapest fixes. Extraction is essential where engines operate indoors and is often a legal necessity. A sealed, marked floor is easier to clean, safer, and helps locate dropped fasteners.

Floor marking is crucial. Marked bays, walkways, and storage areas are inexpensive and maintain layout integrity, which otherwise deteriorates in months.

Test a change before committing.

Layout changes can easily go wrong, revealing issues only under load.

Temporarily move the trolley, bench, or consumables and work this way for two weeks before fixing anything. What seems better on a quiet Tuesday may not be on a busy Friday, and the workers will know quickly.

Ask them. Technicians can quickly identify the two main time-wasters, and their insights are more reliable than any diagram, as they are the ones on the ground.