In an Alabama assembly plant, parts came in cardboard boxes. The plant had a constant flow of parts boxes to the assembly lines, where operators would take out the parts as needed and then discard the boxes as they became empty.
The supervisors pulled the boxes and packing material away from the machines, and tossed it all in piles against the switchgear to get it off the manufacturing floor. This unsafe practice hadn’t yet caused a fire, but it was a ticking time bomb.
Never allow combustibles to accumulate and never let them be placed near electrical equipment. You can often solve chronic combustible misplacement with small work process changes.
In this case, the new work process used a Kanban system that included color-coded parts bins and designated bin collection carts. All that unpacking and tossing of materials took place in a receiving room. This also removed several tripping hazards and some distractions. Quality went up along with safety, while cost went down.