Helping FCC Environmental Get Organised with Bespoke Lean 5S Shadow Boards
When FCC Environmental, operators of the Gloucestershire Energy from Waste facility, wanted to bring better organisation and visual clarity to their tools and equipment, they turned to us for a full Lean 5S shadow board solution.
This wasn’t just about making things look neat — it was about improving site safety, efficiency and accountability across every operational area of the facility.
This was their first time implementing shadow boards across their site. To make sure everything was right first time, we carried out a full site audit. That included measuring up all ten locations, reviewing fixing options for a wide range of surfaces, and meticulously measuring every single tool.
(Side note – it was our first time touring an Energy from Waste plant, and it was genuinely fascinating!
These facilities are impressively high-tech and environmentally conscious, with emissions, dust, and output all monitored closely. More on that here.)
Custom-Sized Lean 5S Boards for Every Corner of the Plant
We designed and manufactured 10 bespoke shadow boards, each one tailored to its location:
Fixings: Supplied with appropriate hooks and supports to suit the specific tools in each area.
Materials: Printed and laminated onto heavy-duty aluminium or composite sheet, built to last in an industrial setting.
Fitting surfaces: From concrete walls to railings and structural posts – we provided solutions for them all, including:
- Sign channel and banding for posts that can’t be drilled
- Channel clamps and post clips for railings
- Traditional wall fixings where possible
Proofing Everything Before We Hit Print
Before production, we printed every design at full scale on recyclable paper so the FCC team could physically test them on-site. That ensured every brooms, hook, shovel and scraper had a perfectly sized home.
Once signed off, we went ahead with production, finishing each board with a durable laminated surface and delivering them by dedicated courier to Gloucestershire.
A Tidy Site and a Safer, Leaner Operation
The new shadow boards have helped transform FCC’s operational areas — providing clearly labelled storage for tools, cutting down time wasted searching for equipment, and making the site safer and tidier. Each board reinforces the principles of Lean 5S: Sort, Set in Order, Shine, Standardise, and Sustain.
Need Shadow Boards Like These?
Whether you're running an industrial facility, a warehouse, or a manufacturing site, Team Mobad can help you plan and produce fully bespoke Lean 5S boards that fit your tools, layout, and ways of working.
Get in touch with us to find out more.
