An experimental lean-manufacturing pilot · Farkhad Bazaar, Tashkent
Problem· Solutions· Timeline· Gallery· Results
Lean Garage · Project Case Study

The 45-Minute
Garage

From a 5-hour visit to a 45-minute one

An experimental optimization project at a working auto-service bay in Tashkent. How three engineering and logistics decisions removed the chaos, the waiting, and the wasted stock.

See the case study ↓

Same car. Same bay. A different way of working.

Nothing about the equipment changed — only the order in which things happen. A typical service visit loses most of its time before any wrench is turned: searching for tools, waiting on a part that should have been ordered hours earlier. Lean Garage removes that waiting, not the work.

Typical service
210min
3–5 hours, most of it waiting
Lean Garage
45min
kit ready before the car arrives
01 — Before & After

What actually changed at the bay

Unsorted parts and cluttered storage before the redesign

Before: parts and tools stored wherever there was room

Before optimization
Service time3–5 hours
Searching for toolsup to 40 min
Waiting on parts1–2 hours
Specialty-oil stockat risk of spoiling
Fully organized tool cabinet after the redesign

After: every tool has one place, and it's always there

Lean Garage
Service time45 minutes
Searching for tools0 min (5S + kitting)
Parts on hand100% before arrival
Stockuniversal fluids only
02 — Three Solutions

Not one big idea — three small ones, each removing a different delay

Preparing the bay before the car arrives
Solution 01
Just-in-Time
Pre-Booking
Fully kitted tool cabinet, 5S organized
Solution 02
Kitting &
5S
Universal ePWR fluid, rated for both combustion engines and EVs
Solution 03
Universal
Fluids

Just-in-Time

The client books ahead. Before the car ever arrives, the mechanic has already ordered and staged every part the job needs. The car pulls into the bay and work starts immediately — no parts run, no searching.

Kitting & 5S

Every job at the shop falls into one of four categories — tires, alignment, full inspection & diagnostics, or oil change. Each has its own mobile kit box holding the complete set of tools it needs, from screwdrivers to specialty wrenches. The mechanic grabs one box and starts the job — no walking the shop for a missing tool.

Universal Fluids

Switching to universal synthetic oils and technical fluids that serve both classic combustion engines and EV cooling and gearbox systems — the bottle pictured above is rated for Tesla drivetrains as well as standard ATF applications. No more slow-moving specialty stock going stale on the shelf.

03 — Timed Side by Side

210 minutes vs. 45 — the same oil change and inspection

Each block is a real stage of the job. Width is proportional to time spent.

Typical service210 min
Arrival Diagnosis 20m Tool search 30m Parts order 120m Work 40m
Lean Garage45 min
Arrival Kit box ready Work 45m

Parts are pre-ordered before the car arrives — that stage doesn't count against visit time.

Old oil draining during a real timed service
Timed on the shop floor

These numbers aren't projections — they're clocked from real jobs at the test bay, drain pan to torque wrench, with a kit box already staged before the car pulled in.

05 — What the Pilot Showed

Three numbers that matter to the customer, the mechanic, and the stockroom

−80%

reduction in service time — from 3–5 hours to 45 minutes

×4

increase in bay throughput per shift

Zero

losses from specialty-fluid spoilage or write-offs