So me and the owner at the shop I work at are trying to find a solution for all of the parts we cut for rails and stiles.

On an average day we build from 250 to 300 doors and drawer fronts. But we'll have multiple jobs cut waiting for assembly. I need help coming up with a solution to keeping these parts organized we have the labeled from the machines by cabinet number, but when you have 80 to 100 per house it's nearly impossible to keep them together on the carts we have now.

It's a four level cart nothing special. But our idea is having cubbies for each cabinet number but I don't want to mix the drawers with the doors then we'd be sorting parts just as we are now.

So to sum it up do any of you have any examples of things you use in your shop?

We want to be able to grab out rails and stiles and the panel for the door and be able to build with zero sorting.

Another one with dividers

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How do you assemble doors?

As an example I assemble tallest doors first.
If there's more than one width of that particular door height, I assemble widest to narrowest.
Then move down the list.

Panels are cut and stacked in that order.
Stiles are cut and stacked longest to shortest.
Rails are cut and stacked longest to shortest as well.

I grab the longest stiles, the next panel, measure the panel to get the rail length.
Glance at the cut sheet to make sure something isn't going stupid on me.
Then assemble.

I'm not doing anything fancy for carts. Just three level general use carts with a welded steel frame. They have many applications.

You're doing WAY more doors than I am though. I think what I'm doing wouldn't fit for that much throughput.

Are you using an optimizing saw I assume? That throws a wrench in it since you might not have a repeat part in the same stick.

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1 option is to reduce batch size and work to a 1 piece flow. If your bottlneck is assembly and you are producing more parts than you can assemble, you now have more inventory sitting idle. Everything you do between cutting parts out and actuall assembly is waste.
Try cutting parts for one job at a time then look at separating out that into smaller runs so you can match the rate of assembly.
Check out this video from Brad and how it changed output

https://youtu.be/OnxsTJUPKcw