Shortening loading time by 38% at the plant in Tczew
The steel structure producer was losing 4,800 PLN a day due to truck queues. We changed the notification system and maneuvering square layout in 19 business days.
In March 2024, we entered the Stal-Bud System floor in Tczew. The problem was visible to the naked eye: a string of trucks blocked the access street, and forklifts drove without a load for 43% of working time.
The challenge
The client faced huge chaos in the maneuvering square. Every morning from 7 to 11 cars reported before the gate without any schedule. The average driver waiting time for loading was 167 minutes. This generated real financial losses – exactly 4,827 PLN every day in the form of penalties for downtime and warehouse personnel overtime. There was a lack of clear communication between the sales office and the weight, so no one knew which goods had priority.
Our approach
Our team, led by Marek Wiśniewski, spent 6 days in the square and warehouse, counting every forklift move with a stopwatch in hand. We look for losses on the floor, so we didn't sit in the office. We analyzed 347 recent loading operations to find bottlenecks. It turned out that most time was wasted searching for finished steel elements that were stored in 4 different sectors without a logical key.
The solution
We implemented a simple digital notification system that eliminated paper invoices at the entry stage. We changed the organization of the maneuvering square, painting 17 new guiding lines and designating 2 permanent buffer zones. We introduced rigid 45-minute time windows for external suppliers. Additionally, together with 14 warehouse workers, we reorganized the delivery zone using the visual stock management method. Now the warehouse worker sees from a distance which profile is ready to leave.
Results
After 19 business days, the chaos under the gate disappeared. Numbers don't lie – we recovered worker time and real cash that previously escaped in the form of logistics penalties.
Timeline
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12 March 2024Work time measurements of forklifts and analysis of queues under the gate.
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19 March 2024Workshops with 14 warehouse workers and change in the delivery zone layout.
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28 March 2024Launch of digital notification and painting new lines in the square.
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14 April 2024Final audit and verification of financial results.
"I was afraid that consulting was just more spreadsheets in Excel. Baltic Bridge simply took paint, painted the square, and sorted our schedule. Finally, there is silence under the gate, and the money stays in the company."