In a repair line, one missing high-use part can ripple downstream, slowing work far beyond the technician’s station.
At the Reconext Bydgoszcz facility, our team implemented a Kanban rack supported by a Light-to-Pick system to keep repair components closer to the point of use. Technicians can now retrieve high-use parts directly instead of creating additional part orders during the repair process.
Bringing Common Parts Closer to Repair
The Kanban rack gives technicians controlled access to frequently used components near the repair area. Each part has an assigned location on the rack.
By moving these parts closer to the point of use, the Bydgoszcz team reduced avoidable interruptions in the technician workflow. The rack also separates routine part demand from less frequent material requests, allowing technicians to use the Kanban process for common components while the warehouse team continues to manage broader inventory control.
Guided Picking at the Rack
With a single button press, the selected part locations illuminate on the rack, guiding the technician to the right storage positions.
Visual guidance reduces the searching and checking that can happen during manual picking. Instead of scanning the rack for each component, the technician follows the illuminated locations and retrieves the required parts.
A wrong pick can create rework, delay the repair, or send the technician back to the rack. By making the correct location visible, the Light-to-Pick system helps reduce those risks at the point where the pick happens.
Replenishment Built Into the Workflow
Each storage location has a predefined minimum stock level. When inventory falls below that threshold, the system generates a replenishment task for the warehouse team.
The replenishment process keeps part availability connected to actual usage. As technicians consume components from the rack, the warehouse team receives the signal to restock before shortages interrupt the repair flow.
A More Reliable Parts Flow
The Kanban and Light-to-Pick system removes repeated friction from the repair process. Parts are available where technicians use them, and the rack shows exactly where selected components are located. When stock drops below the minimum level, replenishment moves back to the warehouse team without requiring a separate technician request.
At Reconext, operational improvements like this support a broader goal: helping repair teams work with more speed, accuracy, and consistency. By improving how parts move through the Bydgoszcz facility, we’re helping keep repairs moving and strengthening the reliability of the services we deliver to customers.
