Silo Walkway Anti-Slip Safety Improvement
A practical, fast-deploying anti-slip treatment for a silo access walkway that had become hazardous in wet and dusty conditions — now being rolled out to further walkways across the site.
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Continuous Improvement & OEE
Production Line Changeover & 6S Improvement Project
A practical 6S and changeover improvement project within a high-volume manufacturing facility — bespoke mobile shadow boards brought tools and change parts to the point of use, reducing search time and supporting faster, more repeatable changeovers.
The Challenge
As part of a wider Continuous Improvement and 6S programme within a high-volume manufacturing facility, DEVA Maintenance was asked to support improvements to production line changeovers. A review of the existing process identified opportunities to reduce wasted movement, searching time and unnecessary delays caused by tools and change parts not being consistently organised or positioned at the point of use. These small losses were contributing to longer changeover times and reducing overall production availability.
The Solution
Working around the requirements of the production teams, DEVA Maintenance identified the tools and change parts required for each line and developed practical improvements to support faster, more consistent changeovers. The project included:
- Identifying opportunities to simplify and improve the changeover process
- Designing and manufacturing dedicated tools and change parts
- Standardising the equipment required for each production line
- Designing bespoke shadow boards around the actual tools and components in use
- Applying 6S principles to improve organisation, visibility and point-of-use storage
- Fabricating robust mobile shadow board frames
- Installing castors to allow the boards to be positioned where required during production and changeovers
The Result
The completed system provided production and engineering teams with a clear, standardised location for the tools and change parts required during line changeovers. By reducing time spent searching for equipment, improving point-of-use availability and standardising the changeover setup, the project helped reduce non-value-added activity during planned production stops.
- Faster and more repeatable changeovers
- Reduced unnecessary operator and technician movement
- Improved workplace organisation through 6S
- Better control of tools and change parts
- Increased production availability
- Improved OEE through a reduction in changeover-related downtime
The mobile design also allowed the shadow boards to be moved between suitable working positions, giving the production teams flexibility without losing the benefits of standardised organisation.
Services delivered
Continuous ImprovementOEE Improvement6S Workplace OrganisationChangeover OptimisationMechanical Design & FabricationProduction SupportManufacturing Efficiency
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