PROJECT OVERVIEW
Between January and April, a four-month improvement project was carried out in the Fitting Shop Equipment area, led by Steven Fletcher and Ollie Clarke. The objective was to create a cleaner, more efficient, and visually organised workspace. By adopting the 5s methodology – Sort, Straighten, Shine, Standardise and Sustain – the team aimed to reduce time wasted by engineers searching for tools and materials, enhance inventory management, and streamline daily operations.
SCOPE OF WORK
The project focused on decluttering the workspace, reorganising stock, and implementing systems to ensure ongoing order and efficiency. Below are the specific improvements made in different equipment areas:
Fasteners and Fixings
- Replaced all old fixings with new ones, ranging in size from M4 to M30
- Introduced a colour-coded system for quick identification:
- Metric Hex Heads – Blue
- Metric Socket Caps – Black
- Stainless Steel – Green
- Imperial – Red
- Organised by fixing type, thread size and length (e.g., M10x50 Hex Bolt)
- Result: Quicker restocking ands reduced search time
Eyebolts and Shackles
- Stocked up on frequently used eyebolts and shackles to prevent delays
- Organised on racks by thread type: metric on the left, imperial on the right, and D shackles on a separate rack
- Implemented a booking in/out system to maintain accurate stock records
All Thread Bin
- Removed the old shelving and disposed of scrap threads
- Installed labelled slots for each thread size for easy identification
- Expanded stock from M5 to M36 sizes
SKF Equipment Board
- Centralised all SKF tools including 2-legged pullers and bearing heaters
- Created a labelled plywood panel for organised storage
- Reused shelves for larger items stored below the panel
Pump Endcap Storage
- Designed a CAD-modeled storage unit specifically for pump end caps
- Improved visibility and accessibility to quickly find the correct end cap
KEY HIGHLIGHTS
- 5S Implementation: Full application of Sort, Straighten, Shine, standardise and Sustain to transform the workspace.
- Increased Stock Variety: Notably expanded the range and organisation of fasteners and all-thread inventory
- Time Efficiency: Engineers now spend significantly less time searching for tools and components
- Improved Visual Management: Colour coding and clear labelling across all storage areas enhance quick recognition and restocking
- Systemised Inventory Tracking: Introduction of booking systems and frequently used components like shackles and eyebolts ensures accountability and stock reliability
This successful transformation has made a lasting impact on workshop operations, increasing both productivity and employee satisfaction
WHY CHOOSE HAYLEY 247 DEXIS
HAYLEY 247 DEXIS demonstrates a strong commitment to operational excellence. This project is a testament to the team’s proactive approach to workplace organisation and efficiency. By implementing lean principles and designing custom storage solutions, the company has significantly improved equipment accessibility, inventory control and workspace cleanliness – all contributing to reduced downtime and faster job completion.
