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I think it all starts with a well planned work shop, where the logistics are organized to fit work style and tooling, and the work space layout accordingly makes effective use of the available space.

I do all my work on finished, or near finished instruments on my large, free standing work bench. No tools over it, so nothing can fall down on it, and enough space around it so it's hard to bang an instrument on anything nearby. My most frequently tools and parts are available at arms length across from the bench, and I try to only keep those I'm using for the task at hand at the bench, and then put them back. I also try to keep the shop fairly tidy all the time, and clean up shavings and debris quickly. I'm not a clean freak by any means, but I think this helps me keep focused, and clutter tends to make me less effective and careless, which is when accidents usually occur. More or less dedicated work stations for making parts, glue-ups, sharpening etc. are spread out along the walls, and all the large machines are in a separate room (also good for dust control). Protective padding, carpet, towels etc. where needed all help (remember to toss towels as soon as you get glue drips on them...).

This has helped reduce the number of mishaps greatly, compared to working on a narrower, crowded wall mounted bench, with machines and jigs more or less haphazardly spread out, and all sorts of obstacles waiting to bite, and sharp, pointy objects all around. An added benefit is I seldom have to waste time looking for a tool; its always either in my hand, or in its place.

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Rian Gitar og Mandolin

That's a great point. I clean up at least once a day, but it's amazing how trashed my shop gets in that time, and by extension, how much time I spend searching for that little plexiglass scroll template, three-sided needle file, etc. I hereby vow to heed your sage advice, and start cleaning up after each operation. It seems like a good way to improve shop efficiency.

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Mountain Song Guitars www.mountainsongguitars.com