382 documented improvements. 172 days without a safety incident. Zero suggestion boxes.
A.O’C Commercials has served commercial vehicle operators in southern Ireland since 1980.
They’re Cork’s authorized Scania dealer and Schmitz Cargobull service partner, running 24/7 call out service with a 40-person team.
Director Padraig O’Connor built a culture around elimination of waste and respect for the individual. Their workshop runs on visual systems, tool tracking, and clear standards that keep technicians focused on fixing trucks instead of searching for parts.
They prove lean principles work in service environments when you combine customer focus with operational discipline.
Sector: Dealership & Service
HQ: Ireland
Customer since: 2024
SOPS: 50+
Kanban: 80+
Other Tools: Skills
Full lean tour
A.O’C Commercials lean journey shows what happens when you trust frontline workers to fix their own problems. They’ve logged 382 completed improvement cards since starting. The real number is higher because many small fixes never get documented.
Safety is their top board metric. They hit 172 days without a safety incident by actually counting and caring about it.
Their morning meeting system combines physical boards with digital screens. Everyone sees the same info. The daily safety walkthrough keeps awareness high. Each day includes waste education that rotates format based on who’s hosting.
The tour showcased real workshop improvements made by technicians who know the work best.
Key Takeaways:
- Trust frontline workers to solve their own problems: A.O’C logged 382 improvement cards by letting technicians identify waste and build solutions. Yuri designed scaffolding because ladders were dangerous. Krzysztof organized parts because he was tired of answering questions. Murray built charging stations because dead laptops delayed work. The improvement card washing line makes progress visible to everyone.
- Make safety something you count, not just talk about: They hit 172 days without incidents by tracking the number publicly and running daily safety walkthroughs by area. Each morning meeting starts with safety awareness. When you measure it and discuss it daily, people pay attention. Before they started counting, incidents were more frequent than they realized.
- Put visual standards where the work happens: Kanban instructions live beside the cards. Tool tracking boards sit in the workshop. 3S checklists hang at work areas. QR codes attach to pull cards. When standards exist at the point of use, people actually follow them. No searching for procedures. No interrupting others for information.
MORNING MEETING
382 Improvement Cards: How This Team Tracks Safety and Progress Daily
A.O’C runs structured daily meetings using physical boards and digital screens to keep their 40-person team aligned on safety, tasks, and continuous improvement.
TAKEAWAYS:
- Safety counter displayed prominently showing 172 days without incident
- Improvement card washing line shows 382 completed cards since start
- Daily waste education rotates format based on meeting host
- Attendance tracking helps with scheduling across departments
- Completed improvement cards presented daily to share learning
IMPROVEMENT
Yuri Replaces Ladders With Mobile Scaffolding and Pulley System
Yuri replaced hassel-ridden ladder work with mobile scaffolding and added a pulley system to lift heavy deflectors safely onto truck roofs.
TAKEAWAYS:
- Mobile scaffolding with wheels replaces ladders on trucks
- Front platform extension fills gap to cabin for better access
- Pulley system borrowed from kayak lifting eliminates two-person ladder climbs
- Heavy roof deflectors now installed safely by one person
- Worker-designed solution addresses both safety and efficiency
IMPROVEMENT
Color-Coded Tools and LED Cabinets Stop Workshop Wandering
Wurth vending cabinets dispense consumables with card tracking, upgraded with LED lights and a visual tool tracking board.
TAKEAWAYS:
- Vending machines track who takes what consumables
- LED lights added to dark cabinets for visibility
- Color-coded personal toolboxes with overhead LED lighting
- Communal tool tracking board shows who has which tools
- Eliminates workshop wandering looking for tools or asking colleagues
LEAN
From Buckets to Bins: One Technician's Parts Organization System
Krzysztof transformed parts storage from buckets into organized bins and created a visual gearbox tracking system with complete service history.
TAKEAWAYS:
- Sorted bins replaced buckets of mixed nuts, bolts, fasteners
- Self-service system frees Krzysztof from constant interruptions
- Gearbox racks moved from floor pallets to organized storage
- Serial numbers, registration, and service history now visible
- Anyone can find parts without asking the only person who knew locations
POKE A YOKE
This Charging System Makes Dead Diagnostic Laptops Impossible
Murray created grab-and-go diagnostic boxes where laptops charge automatically in slot-specific positions with all equipment included.
TAKEAWAYS:
- Each laptop box contains all diagnostic equipment together
- Charging connectors built into back of boxes
- Slot-specific charging prevents mixed up chargers
- Green light confirms charged status
- Eliminates searching for cables, dongles, or charged batteries
SOPs
How 3S Standards Posted at Work Areas Actually Get Followed
The team uses GembaDocs cards to document their 3S housekeeping standards with clear daily checklists for each work area.
TAKEAWAYS:
- 3S standards documented on GembaDocs SOPs at work areas
- Daily housekeeping tasks clearly outlined
- Standards visible where work happens
- Simple format keeps expectations clear
- Increases probability of proper execution
KANBAN & SOP
QR Codes and Visual SOPs Make This Kanban System Work
A.O’C runs two-bin Kanban systems with detailed SOPs at point of use and QR codes on pull cards for easy reordering.
TAKEAWAYS:
- Visual SOPs explain exactly how to handle Kanban cards
- Standards posted beside where cards are used
- Two-bin system with clear location markers
- QR codes on pull cards enable quick ordering
- Clarity at point of use increases system compliance
