Helping FCC Environmental Get Organised with Bespoke Lean 5S Shadow Boards
When FCC Environmental wanted to improve tool organisation and visual management at the Gloucestershire Energy from Waste facility, they asked us to design and produce a full set of bespoke Lean 5S shadow boards.
The work originally began while the site was operated by Urbaser, and the facility is now operated by FCC Environmental, so this case study reflects the current site operator who we worked with to complete the project.
This was about much more than tidying up tools. The aim was to make equipment easier to find, easier to return, and easier to manage across the site, helping support safer working, better housekeeping and a more consistent approach in each operational area.
As this was the site’s first time introducing shadow boards across the facility, we started with a full site survey. Natasha visited the site to measure all ten board locations, review fixing options for different surfaces, and carefully measure the tools that needed to be stored on each board.
It was also our first time touring an Energy from Waste plant, and seeing the site up close was genuinely fascinating. The scale, engineering and attention to environmental control across the facility were seriously impressive.
From that survey, we designed and manufactured 10 bespoke shadow boards, each one tailored to its location and the tools it needed to hold. The boards were printed and laminated onto heavy-duty aluminium or composite sheet, giving the site a durable solution suited to an industrial environment.
Because the boards were being installed in a range of different areas, we also had to plan the right fixing method for each one. Some were mounted to walls, while others needed to be fixed to railings, posts or structural elements where drilling was not possible. We supplied the appropriate channels, clamps, banding and fittings needed to suit each location, along with the correct hooks and supports for the tools themselves.
Before going into final production, we printed each board design at full size on recyclable paper so the team could test them on site. This gave them the chance to check that every broom, shovel, scraper and hook sat exactly where it should before sign-off. Once approved, we produced the finished boards, applied a durable laminate, and delivered them by dedicated courier to Gloucestershire.
The finished boards have helped bring clear, consistent tool organisation to the site, with a designated place for each item and a more visual approach to housekeeping. As well as making the areas look more organised, the boards support the core principles of Lean 5S by helping teams keep tools in the right place, reduce time spent looking for equipment, and maintain tidier, safer working areas.
If you need bespoke Lean 5S shadow boards for a plant, workshop, depot or industrial site, we can help.
From site survey and proofing through to production and fixing options, we make boards that are designed around your tools, your layout and the way your site actually works.
