Improving Safety, Efficiency and Compliance Through Custom Lifting Tackle Shadow Boards.
Mondelēz
International
Sector: Food Manufacturing
Services: Visual Management Design | Shadow Board Manufacture
About Mondelēz Chirk
The Mondelēz International manufacturing facility in Chirk, North Wales, is one of the company’s key production sites, manufacturing well-known confectionery products for the UK and international markets.
Operating a high-volume manufacturing environment, the site places significant emphasis on safety, operational excellence and continuous improvement to ensure production runs efficiently while maintaining the highest workplace standards.
The Challenge
The engineering and maintenance teams at Mondelēz Chirk required a more effective way of storing their lifting accessories, including chains, slings, shackles and other lifting tackle used during maintenance activities.
Although the equipment was available, there was an opportunity to improve the visual organisation of the lifting gear, making it quicker to identify the correct equipment, ensuring every item had a designated storage location and supporting LOLER compliance through improved housekeeping and visibility.
The objective was to create a safer, more organised working environment where missing equipment could be identified immediately and lifting accessories were protected from unnecessary damage or incorrect storage.
The Design Process
Every Peak VM project begins with understanding the customer’s exact requirements. Working closely with the engineering team at Mondelēz Chirk, we carried out a detailed assessment of the lifting tackle to be stored, ensuring every chain, sling, shackle and accessory was accurately measured and allocated its own dedicated location.
Using this information, our design team produced detailed 3D visualisations of the proposed shadow boards, allowing the customer to see exactly how the finished solution would look before manufacture began. This collaborative approval process gave the engineering team the opportunity to review layouts, suggest refinements and ensure the boards would integrate seamlessly into their maintenance environment.
Throughout the project, our onsite support proved invaluable, enabling final adjustments to be made during the design phase and ensuring the finished boards met the operational needs of the site. By combining digital visualisation with practical engineering expertise, Peak VM delivered a bespoke solution that fully aligned with the customer’s vision before production even started.
The Solution
Peak VM worked closely with the Mondelēz engineering team to design and manufacture a series of bespoke lifting tackle shadow boards tailored specifically to the equipment used on site.
Every lifting accessory was individually measured and incorporated into a custom board layout, creating a dedicated location for each item. Clear visual shadows, equipment identification and logical positioning make it immediately obvious when equipment is missing or stored incorrectly.
Manufactured using heavy-duty materials and fixings suitable for industrial environments, the shadow boards were designed to safely support the weight of lifting equipment while providing a durable long-term visual management solution. Positioned within the maintenance areas, the boards ensure lifting tackle is always stored close to where it is required, reducing wasted time searching for equipment and encouraging consistent working practices.
The Result
The bespoke lifting tackle shadow boards have delivered immediate benefits for the maintenance team at Mondelēz Chirk, including:
✅ Improved organisation with a dedicated location for every lifting accessory.
✅ Faster equipment retrieval, reducing time spent searching for lifting tackle.
✅ Supports LOLER compliance through organised storage and improved equipment control.
✅ Enhanced visual management, making missing equipment instantly identifiable.
✅ Safer, more efficient maintenance operations with purpose-designed storage solutions.
Client Testimonial
