Expert technical report for the analysis of the organization required to ensure production capacity in response to the forecast increase in demand
Borg Automotive & ITEMSA
Analysis of the organization required to ensure production capacity in response to the forecast increase in demand
Initial situation
Borg Automotive Spain Turbo Motor Inyección, S.L.U. (BASP) is an industrial company in the automotive sector located in Imarcoain (Navarre, Spain) and part of Borg Automotive Group since 2020, with a high percentage of its sales focused on exports and, specifically, on the European market.
The company specializes in the production of remanufactured automotive turbochargers for OEM vehicle manufacturers, OES (Original Equipment Supplier) providers, and major automotive aftermarket distribution groups.
BASP is the only Borg Automotive Group plant manufacturing this product for the European market and, therefore, is the turbo competence centre and is highly specialized in its remanufacturing, focusing its operations on the production of these products.
Its integration into Borg Automotive Group and the strengthening of the international commercial structure enabled the company to expand its presence in new markets and reinforce its position in existing ones. As a result, sales forecasts for the 2025-2029 period anticipated significant growth in activity, with an evolution that implied more than doubling production requirements compared to current levels.
Against this backdrop, BASP needed to analyse which production and organizational measures should be implemented in order to meet the forecast increase in demand and ensure the required capacity across all processes affected by the growth.
General intervention plan
Itemsa carried out a technical study with the aim of defining the organization required in terms of work shifts and operational sizing for the coming years.
The intervention focused on analysing the plant’s current situation, assessing the available production capacity, and determining the organizational requirements needed to absorb the forecast growth while maintaining the required service levels.
Actions
- Visit to the company’s facilities in Imarcoain to understand the work carried out there and the general characteristics of the different job positions.
- Meetings with the management, technical and supervisory teams to understand the planned growth levels and the needs of each area in terms of technical-practical knowledge and experience required by employees performing the different functions, as well as to gather the necessary information.
- Analysis of the information collected during the visit, together with the information subsequently provided by BASP.
- Identification of the production and organizational measures recommended according to the situation analysed.
- Preparation and presentation of the technical report.
The study included an analysis of facility capacities, cycle times, staffing requirements, training processes and qualification matrices across the different production areas.
In addition, the productivity improvement potential of the production sections was assessed, and different development scenarios were prepared in order to size the future needs of the organization.
Objectives
- Analyse the production and organizational measures required to meet the forecast growth in demand.
- Determine the organization required in terms of work shifts in the positions affected by the increase in activity.
- Ensure the production capacity required to meet future production forecasts.
- Identify possible workforce expansion and operational reorganization needs.
- Ensure the availability of qualified personnel across all work shifts.
- Maintain the service levels and responsiveness required by customers.
Results
The expert technical report provided Borg Automotive Spain Turbo Motor Inyección with an objective view of the production and organizational requirements arising from the forecast growth in activity over the coming years.
The analysis carried out by Itemsa identified a productivity improvement potential of 25% in the disassembly area and 10% in the assembly area. In addition, the technical study helped size future requirements according to the different expected levels of production capacity, identify the necessary evolution of work shifts and determine the organizational measures required to respond to forecast demand growth involving an increase of more than 200% during the 2025-2029 period.
Finally, the project made it possible to define a roadmap for progressively adapting the plant’s organization, ensuring the availability of qualified personnel, balance between shifts and the necessary support from auxiliary areas to accompany the company’s growth.
The expert technical report made it possible to define the recommended production and organizational measures required to adapt BASP’s organization to the forecast growth over the coming years.
