5S Workshop

A traceability-led 5S workshop for major automation specialist

The challenge

A team of automation engineers needed a 24-man workshop that could hold all the tools required to perform maintenance across the processing site of a major UK retailer. The workshop needed to include specific tool kits that were easy to transport, as well as storage and shadow boards that provided total traceability and ease of auditing.

The solution

ABCO and Beta Tools designed and installed a workshop designed around traceability, ease of auditing and making tools readily available in the event of a breakdown. Furthermore, ABCO created a stores area to hold spare parts for the site, creating a complete maintenance solution for this 24-strong team of engineers.

Results

The stores and traceability-led workshop was installed over four days. This was followed shortly after by the arrival of a comprehensive package of consumables and spares that are now managed by ABCO on a weekly basis.

24 roll cabs and individual toolkits
2 secure shadow boards for shared tools
Shared cupboards and roll cabs for larger jobs
Charging cabinet for tablets and power tool batteries
Access to air and power throughout the workshop
Stores locations for 5k parts

“Using the Japanese 5S methodology for workspace organisation, we were able to create a tidy, efficient and fully traceable workshop for this large team of engineers. Everything about this workshop was geared towards ease of auditing, from the individual tool kits to the shared cupboards and roll cabs for larger jobs. When a workshop is easy to audit, safety, cost and tool usage are easy to record, optimising efficiency and promoting operational uptime for the facility being managed – something that helps attract quality engineering talent during recruitment.”

James Gibson

Managing Director, ABCO

Case Studies

Air Leak Survey

Value add air leak surveys deliver monthly energy savings of £4,000

A global leader in metal packaging wanted to lower their energy usage by identifying air leaks on their line. They wanted to implement an ongoing, proactive air leak survey program but were concerned about the ongoing outsourcing costs.

Urgent PPE Supplies

£100k per day in revenue safeguarded for major construction materials supplier

A leading supplier of construction materials, urgently needed 250k certified face masks so their teams could support government efforts to build temporary hospitals and testing centres during COVID 19. Let down by their usual PPE supplier, they faced revenue losses of £100k per day.The masks needed to be genuine and fully certified and they were needed within a 48-hour timeframe.

5S Workshop

A traceability-led 5S workshop for major automation specialist

Vending Solutions

Vending machine management delivered £14,000 annual saving for major manufacturer

A leading packaging manufacturer had an existing vending solution, supplied by a major competitor. Service standards began to slip and costs began to creep up. Replenishment was inconsistent, the quality of data was poor and unapproved product swaps were added to vending inventory.

All case studies