Automotive manufacturing
Line-side tool boards for a tier one automotive supplier
Twenty-four assembly cells, one visual standard. A programme of line-side tool boards designed from the customer's tool lists and installed over two weekends.
Client
Tier one automotive supplier, West Midlands
01
Challenge
Each cell had evolved its own arrangement of tools and improvised boards. Internal audits repeatedly flagged missing or unhomed tools, and operators reported regular searches for shared items between adjacent cells. [PLACEHOLDER: replace with real detail.]
02
Approach
We surveyed each cell, consolidated the tool lists, and proposed a common board format with cell-specific inserts. Proofs were reviewed with team leaders before manufacture. Installation was phased to avoid production loss. [PLACEHOLDER]
03
Outcome
All 24 cells now share a single visual standard. The site reports fewer tool-related micro-stops and a clean sheet on the following customer 5S audit. [PLACEHOLDER: replace with measured figures.]
Project images
On site
Tool shadow board, assembly cell 
Mobile cleaning station, paint shop
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