Fourways
Fourways prototype cell
A Fourways metalworking yard trialled our MeasureKit Fab in a real bay, fine-tuning their workflow before committing to new jigs and fixtures for daily use.
A busy Fourways metal shop with real layout headaches
The Fourways yard needed a reliable way to check welds and parts before moving to full production, but their bays are tight and every shift has different people on the floor. With bakkies loading at the door and shared grinders in high demand, they struggled to keep measuring tools organised and available for everyone.
Their main problem was inconsistent checks between days and shifts, especially on fillet welds and part dimensions. The foreman wanted a better way to log checks, keep tools safe from knocks, and still allow quick access during busy changeovers.
Setting up a test bay with MeasureKit Fab and floor cards
We kitted out a prototype cell with our MeasureKit Fab set: 150 and 300 mm callipers, squares, fillet weld gauge set, all in a foam case with a shift log card. The cell was marked out next to their main grind area, close enough for teams to use during production without crowding the loading zone.
Printable shopfloor cards were pinned up on the wall for quick reference, showing basic fillet weld checks and calliper care steps. We added a labelled PPE Station Bay on a stand, as the yard cycles through contractors who often forget gloves or visors. The cell was kept clear of permanent jigs to allow the team to simulate new layouts and workpiece sizes each day.
- MeasureKit Fab tools in foam case
- Shift log card and checklists
- Printable floor cards for quick checks
- Mobile PPE Station Bay
- No permanent jigs for easy layout swaps
First-week adjustments and practical improvements
After two weeks, we saw certain issues. The shift log card was being skipped on afternoon shifts, so we moved it to a magnet board above eye level where the next crew clock in. Some crew left tools on the grind deck, so we bolted the foam case to a shelf under the layout table. A few PPE items went missing, so the stand was chained to a post with a clip for used gloves.
A power cut one Monday morning stopped the grinders and welders for an hour, so we showed the team how to catch up checks using the log card and keep prepped parts in a marked rack to avoid confusion during restarts. Crews started using the fillet weld gauge more regularly after we ran a refresher session on SAIW checks and the basics from ISO 9606-1.
Lessons for other yards setting up prototype bays
Any yard trialling new layout flows or metrology tools will hit practical issues with tool storage and shift discipline, especially in busy areas like Fourways. Fixing the log card in a visible spot and anchoring the tool case made the biggest difference here.
Shifting the PPE station and putting clear floor cards up meant new contractors settled in quicker, and no time was wasted hunting for missing visors or gloves. Involve your trainers or foremen in running through SAIW checks early on, and always keep your trial bay clear of permanent jigs so you can adjust layouts as you go.
- Keep tool storage fixed and visible
- Attach log cards near crew entry points
- Use mobile PPE and floor cards
- Run refresher checks with new crews
- Leave layout open for easy changes
Primary gear: MeasureKit Fab. See also jobs and shopfloor.
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