Context and Initial Challenges
BCS Timișoara provides electronic solutions for the automotive industry and other fields with demanding standards. The relocation of production lines led to a sudden increase of more than 60% in the volume of parts, which led to the capacity of the existing warehouse being exceeded. In order to maintain the activity, temporary storage spaces (pallets in general areas) were used.
Critical Issues Requiring Immediate Action
- ✕Frequent shutdowns of production lines
- ✕Difficult access and operational risks
- ✕Low inventory accuracy
- ✕Non-compliance with IATF 16949 and occupational safety standards
BCS Timișoara - Electronics & Automotive
Active in the electronics and automotive industry, went through a process of relocating production lines that generated an increase of over 60% in the volume of managed components.
Analysis of the Situation
The Share IT Smart team carried out a detailed analysis of the existing space and processes:
- •Direct observation of workflows and working methods
- •Analysis of the degree of use of space and equipment
- •Simulation of moving scenarios using the cardboard engineering method
Main Causes Identified
| Problem | Potential Impact | |
|---|---|---|
| Infrastructure not adapted to new volumes | Unable to accommodate 60% increase in component volume | |
| Inefficient manual handling | Increased operational time and safety risks | |
| Lack of a flexible inventory organization model | Temporary storage in general areas causing production disruptions | |
| Non-compliance with IATF 16949 standards | Audit risks and potential certification issues |
Implemented Solutions
A comprehensive approach combining physical infrastructure improvements with innovative logistics concepts.
Operational Optimization
Strategic infrastructure improvements for enhanced efficiency.
- •Construction of a two-level warehouse with a mezzanine accessible without heavy lifting equipment
- •Strategic redefinition of inventory organization to increase safety, operator efficiency and reduce the need for specialization (e.g. forklift drivers)
Innovation and Mobility
Revolutionary mobile warehouse concept.
- •Introduction of a completely new concept of 'mobile warehouse': shelves were lifted and mounted on wheels without being emptied of stored materials, allowing them to be moved as a whole, together with stocks, without disorganization
Project Management and Collaboration
Coordinated implementation with key partners.
- •Full coordination of the implementation by Share IT Smart
- •Active involvement of the customer in defining safety requirements
- •Selection of specialized suppliers: Concita for moving loaded shelves, Tudox for shelf extension and mezzanine construction
Managing Critical Constraints
Delivering results under extreme time pressure.
- •Implementation in just 5 days, including 2 weekend days
- •Zero production stoppages during the entire process
- •Full compliance with strict safety and fire risk prevention requirements
Transformation Delivered in 5 Days
Results and Impact
Storage Capacity Increase
Production Interruptions
Final Storage Locations
Inventory accuracy significantly improved
Faster access to components and efficient handling
Full compliance with IATF 16949 standards and occupational safety requirements
Sustainable solution enabling future growth
Scalability and Sustainability of the Solution
A future-proof approach designed for long-term operational excellence.
Extensibility
Modular design enabling rapid adaptation.
- •The modular mezzanine can be replicated in other areas
- •The organization model with mobile shelves allows quick adaptations to variable volumes
Sustainability
Long-term efficiency and cost optimization.
- •The organization favors cyclical inventory management
- •Eliminating heavy equipment reduces costs and risks
- •Operators are focused on value-added tasks, increasing overall efficiency
Replicable Model
Creating an internal benchmark for excellence.
- •The project becomes an internal benchmark for rapid logistics reorganizations in critical contexts
Key Takeaways
Speed Without Compromise
Demonstrated that even the most pressing logistical challenges can be solved rapidly without sacrificing quality or safety
Innovation in Action
The mobile warehouse concept proved that unconventional thinking can deliver breakthrough results
Zero Downtime Achievement
Successfully doubled capacity while maintaining 100% production continuity
Strategic Model
Created a replicable framework for rapid logistics transformation in critical environments
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