Lean Manufacturing

Adhering to the tenets of Lean Manufacturing we have been able to generate excellent results that translate into bottom-line profits. We have developed a lean way of thinking by implementing various lean tools like: TPM, SMED, Value Stream Mapping, Line balancing, FMEA and 5S.

The goal of Lean Manufacturing at UCAL is to essentially connect the entire value stream and eliminate all forms of waste.

Producing defect free products from defect free equipments making the manufacturing system highly reliable and flexible.

This strengthens and enhances plant’s ability to produce to the customers’ needs, consistently.Total Employee Involvement results in cost reduction in overall manufacturing which would in turn satisfy the customers’ requirements

Total Productive Maintenance (TPM)

  • Producing defect free products from defect free equipments making the manufacturing system highly reliable and flexible
  • This would strengthens and enhances plant’s ability to produce to the customers needs
  • Total Employee Involvement results in cost reduction in overall manufacturing which would in turn satisfy the customers requirements
S. No Parameters Targets
P Output per hour per man > 30%
Downtime Zero
Q In-house Rejection 80% Down
Customer Complaints Zero
C Manufacturing cost 30% Down
Inventory 30% Down
D Delivery Adherence 100%
S Accidents Zero
M Kaizen / Employee 2/Month
Total Employee Involvement 100%

Value Stream Mapping (VSM)

Value-stream maps are the prototypes for lean transformations. At UCAL , we use VSM technique to identify and eliminate waste thereby streamlining work processes. The steps that we follow in implementing the VSM are:

  • Identify the products to map
  • Draw the “current state” map
  • Access and analyze the current state
  • Draw the “future state” map with all the improvements
  • Create a plan to implement the desired state
  • Implement and review the plan

Single Minute Exchange of Dies (SMED)

In this intensely competitive market, there is always a need to provide customers with diversified products of very high Quality while reducing the manufacturing cost at the same time. At Ucal, SMED has been consistently proven to be the key to meet this extremely challenging demand as it reduces waste, time spent between each production runs as well as the size of production lots and inventory.

Other best practices followed at UCAL

  • Kaizens
  • Poka Yoke
  • 5S