Shop Organization
If you have a small shop and you’re feeling jealous of all those warehouse workshops you see on the Youtubes, let’s talk about how to layout and organize your space to act like a big shop. Without as much walking around.
Prioritizing Tools
Minimizing what’s in your shop not only gives you more space to work on your projects, but pushes you to maximize the capabilities of the tools that you really need.
Selecting which stationary tools are most important for a small hobbyist workshop ultimately comes down to what kind of projects you do. A miter saw excels in crosscutting long boards to length. But let’s be real–it’s very difficult to do large projects in a small shop. So in our small shop, a table saw can make all of our crosscuts for us, and maybe more accurately too. 
With that in mind, think about other tools that have overlapping functions to help you decide what you truly need, versus what is simply nice to have. I’ve recently been thinking of removing my drill press from my shop, since I can most likely achieve 80% of what it can do with a drill and a guide. The realization I’m having more and more is that a drill press is not essential for the projects I typically make.
Are there smaller versions of tools you can get by with? Sometimes yes, sometimes no. For instance, I have a 20 gallon air compressor in a storage closet that I always forgot about because I only use it on the rare occasion I bring out my brad nailer. I’m sure I can ditch the whole compressor and buy a cordless nailer…I should probably do that. On the other hand, I have a 12” jointer and a 16” planer. Are there smaller benchtop versions of these tools out there? Sure. Am I willing to compromise on my milling machines? Absolutely not. Even if these examples don’t apply to you, it’s the thought process here that counts.
You may have heard that you should have duplicates of some tools so you can save steps when working around your shop–like having drill bits at your drill press, and having all the same drill bits where you keep your hand drills. While that makes sense for a large shop, we’re talking small shops, and you cannot tell me that taking two steps to grab your drill bits is more of an inconvenience than having extra space for a tool that could potentially boost your productivity.
Layout
Your shop’s layout should be determined by the stationary tools you use the most. And the tool you use the most in your shop? It’s your workbench–you spend 95% of your shop time at your bench, so its placement is priority.
I’m sure like me, you’ve all heard “you need casters on all your tools and cabinets”. While it does help, it’s not going to solve all your layout issues. In fact, I hate when I have to pull out a machine every time I use it. So coming up with a smart layout from the start will save you all this time and hassle.
An easy way to get started planning your shop is to use graph paper, and create a drawing to scale of the walls, doors and any other obstacles in your space. You can then cut out scaled versions of your stationary tools and work surfaces to see where things can work. Graph paper only takes you so far though, since it’s strictly a birds-eye view, so alternatively, you can model your shop in a 3D program like Sketchup. This way, you can not only design a smart floor plan, but also see how to maximize all available volume within.
So you start with your workbench, and then move to your second most used tool–the table saw. My table saw really works as a single unit with my workbench, since the bench also doubles as an outfeed table. I placed them roughly in the center of the room to get the most infeed and outfeed possible, and this is what I try to do with most other stationary tools as well. Thanks to Mr. Pythagorean, who taught me that a rectangular room is longer when measured from opposite corners, that sometimes means putting tools on an angle.
Doors may seem like an obstacle to work around, but they also provide an opportunity. I’ve purposefully set up my table saw so I can open the door to the storage room behind me to increase the max length I can rip. My planer can be oriented so that I can open other doors to increase the max length of board I can plane.
Wasted Volume
You can reduce clutter and increase storage options for essential tools and supplies in your shop that you need close at hand by eliminating wasted space that may be consumed by items you truly don’t need close at hand, or poorly designed shop furniture that doesn’t give you any storage opportunity.
As crazy as it sounds, I think the biggest culprit of wasting volume in a small workshop is wood. One of the biggest reality checks I had was when I once brought home 100 bdft of maple I got for cheap, and realized I had absolutely nowhere to put it. I realized that a small shop is not an ideal place to store wood if it’s taking up room that could otherwise be used for tools. You may have options for storing wood, like in a shed or in a crawl space, but you might need to simply buy the amount of wood needed for each project as they come. Scraps get burnt for firewood, or turned into char-cutting (my clever portmanteau of charcuterie & cutting) boards, but they can easily get out of hand if you are of the “pack-rat” persuasion. A wall-mounted lumber rack could instead be used for a French-cleat wall that’ll make you more efficient when working, or a scrap bin could be swapped for a cabinet to organize your sanding supplies. Be cut-throat about getting rid of scraps.
You know what’s another huge waste of space? Those cheap tool stands that are made out of pressed sheet metal whose only function is to raise up the tool to a semi-acceptable working height (if you’re Frodo Baggins), and in a fairly rickety manner I might add. There is so much wasted volume under them that can be better used for additional storage. Wherever possible, eliminate these stands and build or buy cabinets that have more than one use. I’m guilty of having my router table mounted on a simple two by two frame that I hastily pocket screwed together. If I was smart, I’d build a cabinet with drawers that could house both my router bits and accessories, and my table saw blade and accessories too.
Drawers vs. Cupboards vs. Shelves
Once you’ve eliminated wasted volume, you need to decide how you’re going to use that regained space for storage. There’s closed storage such as drawers and cupboards, open storage such as shelves and tool holders, and wall storage such as pegboards and French cleats. Closed storage keeps dust off your things, open or wall storage gives you easier access to tools, and if you have the available wall space, hanging tools on walls with custom tool holders or French cleats is great.
I don’t really understand the popular idea of “first-order of retrievability” as it pertains to a small shop. The concept is having your most used tools closer at hand. But since everything in a small shop is already either within arms reach or at least only two steps away, I think it’s a moot point.
My issue with wall storage is that after organizing my stationary tool layout, I just don’t have the space. The danger with closed storage is you may collect things and forget about them. That being said, I actually prefer drawers over cupboards or open shelving. Drawers are essentially shelves that you can pull out and you’re able to see and access everything within, and everything within will stay clean and dust free.
Drawer Organization
If you don’t keep drawers organized, they can turn into a complete nightmare. I’ve found that the best way to keep drawers organized is to have a lot of drawers, keep as little in each as possible, have each drawer contain related items only, and create a permanent arrangement within each.
When I designed the drawers in my workbench, I spent time figuring out what exactly I wanted in each. I made the drawers as small as possible, because even if you figure out what you want in each drawer, everything is still loose, messy and completely jumbled around. And there isn’t much stopping me from tossing stuff where it doesn’t belong when I inevitably get lazy. So, more small drawers stay better organized than fewer large drawers.
The key is to plan out each drawer intentionally with similar items that make sense. It’s even a good idea to leave a bit of extra room in a drawer if you’re expecting to add something in the future. 
Simple bins are great for compartmentalizing the space in a drawer. I find these are good for small and similar items such as markers and pencils, dowels, biscuits, etc. If you want to subdivide the space, you can use thin strips of plywood lapped together to make a grid that keeps everything separate. Don’t make them too tall, or you won’t get your fingers in there. Bundle them together with tape to create the laps all at the same time. Not gluing them together allows you to adjust to changes in the drawer content over time.
For the classiest drawer organization, you can splurge for some kaizen foam. You cut it to fit in your drawer, then lay out what you want where on top of the foam. Trace the outline of each tool, cut, then peel back the layers. You can get really deep versions of this stuff, but I don’t find it completely necessary to envelop the whole tool in foam. You just need to create a depression so it doesn’t roll away.
There are obviously more ways to go about organizing drawers: folks with CNCs and laser cutters can do all sorts of cool things with engraving organizers. But the main point I want to emphasize is that creating a home for everything in turn prevents you from putting something else where it doesn’t belong. Remember, less is more in drawers.
Spring Cleaning
You’re always going to be expanding your small tool and gadget collection, it’s a recurring theme in the life of a woodworker. Since your shop space is small and finite, then naturally some things have to go if you want to bring new stuff in.
That’s why approximately once a year I do a deep clean and go through all of my stuff: every drawer, shelf and cabinet. I ask myself if I’ve used this within the past year, if I really need it, and if its function can’t be achieved by another tool already in my shop. If the answer is no, then I’ll consider getting rid of it, or at least put it in storage.
Then I go through my storage and do the same thing. With storage, it’s actually easier to completely get rid of things because I’ve usually I’ve forgotten about what I’ve stored away and made do without it. It feels good to have an annual cleanse so you can make room for the new things you want this year, rather than space being taken up by tools you thought you needed five years ago. I can quite honestly say that I’ve rarely regretted getting rid of anything.
Everyday Cleaning
I used to work in a frame shop, and my manager was a huge stickler for cleaning up everything at the end of each day. I was a little peeved that I couldn’t just leave the same five tools that we used every day on the worktables. But slowly, over time, I began to appreciate coming in each morning to a totally clean shop that wouldn’t cause me any frustration. When everything is back in place, you know where everything is, nothing gets in your way, and you can focus entirely on the task at hand.
I know you want to use all your shop time for making things and not cleaning, but take ten minutes after you finish to clean up the shop. Put your tools back, give your surfaces and floors a quick sweep or vacuum. I’m not talking about a deep clean, just surface-level. When you start skipping this routine, things get messy and out of hand and it takes a lot longer to get back in order. If you clean a little and often, it makes it easy to keep tidy.
Lighting
Something that people hardly ever mention when it comes to shop organization is good lighting. It may be a bit tangential, but whatever. Having a bright shop is really underrated. It’s quite easy to get used to dim lighting, and it’s one of those cases of “you don’t know what you’re missing.” Pick up a bunch of cheap LED strips and go nuts. Or if you want to spend extra money to get fancy lights, sure, but it’s fine if you don’t. My lights are a little unusual because I film videos in my shop, but I bring it up because good lighting just makes everything feel cleaner, and makes a small shop feel bigger.
Final Thoughts
Laying out a shop properly is not a one-and-done activity, because you’re constantly going to be changing and growing as a woodworker, so you’ll be tweaking your layout over time. Shop organization and cleanliness is a constant battle, so build good habits now to keep it in check. 
Having a shop that is well laid out and organized will expand its capabilities, make you more efficient, and overall make your time in the shop more enjoyable.