The trades industry is facing a workforce shortage, making it harder for businesses to find enough technicians to meet demand. But the work does not stop. So how do you get more done with the team you have? The answer is efficiency.
One of the most effective ways to improve efficiency is by applying lean principles, a methodology originally pioneered by Toyota in the mid-20 century and embraced by top organizations worldwide. While often associated with manufacturing, lean principles are just as valuable in the trades, helping businesses optimize workflow and eliminate wasted time.
A well-designed work van or truck setup keeps tools organized, minimizes downtime, and allows technicians to stay focused on the job instead of searching for equipment or dealing with clutter.
WHAT ARE LEAN PRINCIPLES?
Lean principles are all about reducing waste and maximizing value. Waste is not just physical clutter—it includes wasted motion, unnecessary steps, and inefficiencies that slow down work. The goal is to create a streamlined, organized system where every movement and every tool serves a purpose.
Applying Lean Thinking to Your Work Vehicle
1. Organize for Efficiency: A Place for Everything
A disorganized van or truck is a productivity killer. Every second spent digging through bins or searching for a misplaced tool adds up over a workday. Implementing 5S principles (sort, set in order, shine, standardize, sustain) ensures that everything in your vehicle has a designated space:
- Sort – Remove unnecessary items that clutter up your workspace.
- Set in order – Arrange tools and equipment in a way that minimizes wasted movement.
- Shine – Keep the workspace clean and free of debris.
- Standardize – Use the same setup across all vehicles so technicians always know where to find things.
- Sustain – Make organization a habit by regularly reviewing and refining the setup.
2. Reduce Unnecessary Movement: Keep Tools Within Reach
Time spent moving back and forth between the vehicle and the job site is time wasted. Minimize unnecessary motion by keeping frequently used tools and materials within easy reach.
- Install purpose-built storage such as tool drawers or packout systems for quick access.
- Use bed slides to pull the gear towards you, eliminating the need to climb into the vehicle.
- Keep heavy equipment low and light tools high to improve ergonomics and efficiency.
3. Standardize Vehicle Setups for Your Fleet
Inconsistent vehicle layouts slow down teams. If a technician has to use another vehicle with different setup, time is wasted while they get used to the new layout. Standardizing vehicle setups across your fleet ensures every technician can get to work without hesitation.
- Create a uniform layout for all upfits based on common workflows.
- Use labeling systems so technicians instantly recognize storage locations.
- Train teams on best practices to maintain the system.
4. Cut Down on Excess Inventory
Too much inventory takes up space and adds weight to your vehicle, reducing fuel efficiency. Carrying only the essential tools and parts helps minimize excess and keeps your setup lean.
- Use job-specific inventory kits rather than storing everything you might need.
- Implement restocking systems that ensure parts are replenished as needed rather than overloading vehicles.
5. Invest in Time-Saving Equipment
Efficiency is not just about organization, it is also about using the right tools. Equipment designed to streamline tasks can make a stark difference.
- Drop-down ladder racks reduce the strain and time spent loading and unloading ladders.
- Conduit carriers keep materials secure and prevent wasted time retrieving items.
- Lift gates to safely load and unload equipment, reducing strain and saving time.
6. Make Continuous Improvement a Priority
Lean principles are not a one-time fix—they are a mindset. Encourage technicians to identify inefficiencies and suggest improvements. Regularly assess how vehicles are being used and refine layouts or tools as needed.
THE BOTTOM LINE: LEAN UPFITTING = MORE JOBS COMPLETED
In a time when hiring more technicians is not always an option, lean upfitting helps businesses do more with less. By optimizing your fleet for efficiency, you are not just reducing frustration—you are increasing job capacity, improving technician morale, and ensuring your team can complete more work in less time.
about the author
Kathy Fowler is the marketing manager at Sterling Fleet Outfitters, a leading upfitting company specializing in commercial vehicles for trades and service industries. To learn more, visit www.sterlingfleetoutfitters.com.
