I never squad up miners, hunters, or woodchoppers. They are too busy, doing what they do.
A squad is setup to weave and another to gatherer wood. To prevent a soft civilian dwarf from bumping into a nasty critter while outside the fort. I give these guys layered leather, and all that bone/shell crap to wear. No metal, cept for cap and bp.
I've found it better to NOT use barracks as a sleeping quarters; I don't even know why its up in there. My troops are always armored. I never make marksdwarfs, the AI is stupid. Or I just haven't figured out the finer details of getting them plush up against the fortifications.. They always appear to shoot from a pisspoor angle. So no ranged for ol'Knutor.
I prefer obsidian swords. For their flexibility, while I'm dressing the troops up. Or silver maces. Maces hit slightly harder than hammers. I see many FBs die to a Macelord. Well indirectly, I wish there was a death msg in alert scroll, stinks having to bring up the dead unit list to find out if a fight is finished.
My danger room has just one spear in ea of its many traps, and I like to have it deep down in there, so I can mass pit into it. I try to keep water only, for drinking and a well near danger room. I also like to set some bars up, to prevent flying things from getting out of my pit.
I never go on the offensive, until I have a full squad in full armor. Hope that helps you.
Sincerely,
Knutor