Shadow Board
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A shadow board organizes tools with painted outlines showing each tool's designated location, making missing items immediately obvious.
Definition
A shadow board is a visual control tool where each item's designated location is marked by an outline or "shadow" of the item, typically painted on a board, cabinet, or wall. When tools are in place, they cover their shadows; when removed, the empty shadow immediately reveals what's missing and where it belongs. Shadow boards are a classic application of seiton (set in order) from 5S, making correct storage obvious and missing items impossible to overlook. They reduce search time, prevent loss, and simplify returning items to correct locations.
Examples
A maintenance shadow board holds frequently used tools. Each tool's outline is painted on the board in contrasting color. At shift end, a glance reveals any missing tools. New technicians immediately know where each tool belongs without asking or guessing.
Key Points
- Shadow boards make missing items immediately obvious without counting or inspection
- They eliminate "where does this go?" questions—the outline shows exactly
- Shadow boards reduce time searching for tools and increase accountability
- They work for any items that have designated locations
Common Misconceptions
Shadow boards only work for tools. The principle—showing designated locations visually—applies to supplies, equipment, documents, or any items that should have a "home." The concept transcends physical tools.
Shadow boards are permanent and inflexible. Good shadow boards can be updated as needs change. The investment in creating them should be balanced against need for flexibility.