Process Industry

Variability in the chemical composition and mechanical properties of steel can lead to inconsistencies in quality, affecting downstream processing and customer satisfaction.

The energy-intensive nature of steel production contributes to high operational costs and environmental concerns.

Frequent equipment breakdowns due to the harsh operating conditions impact productivity and cause delays.

Complex layouts and suboptimal scheduling often result in material bottlenecks, reducing overall plant efficiency.

Tire manufacturing involves multiple processes such as mixing, calendaring, building, and curing, each prone to inefficiencies and quality issues.

The use of natural and synthetic rubbers poses a challenge in minimizing waste during production while maintaining product quality.

Managing raw material and finished product inventories effectively without overstocking or shortages is challenging.

At Universal Edge Services, we offer targeted solutions that address these critical challenges through the following service offerings: 

• We assess your current operations and develop a tailored roadmap to optimize      processes, enhance productivity, and align with strategic business goals.

• Implementing lean tools such as Value Stream Mapping, 5S, and Kaizen to streamline      workflows, reduce waste, and improve process efficiency.

• Developing a culture of autonomous maintenance and preventive strategies to reduce      downtime and extend equipment life.

• Utilizing Lean Six Sigma methodologies to root out process inefficiencies, reduce      batch variability, and ensure consistent quality.

• Enhancing supply chain reliability through stocking models and improved logistics      management, ensuring timely delivery of materials and minimized lead times.

The flat steel industry involves complex, energy-intensive processes that put significant strain on equipment. Key stages such as hot rolling, cold rolling, and finishing require continuous, high-capacity operation, which makes machinery vulnerable to wear and tear. The manufacturer faced frequent unplanned breakdowns, disrupting production schedules, causing costly delays, and reducing overall throughput. These breakdowns also led to increased maintenance costs, emergency repair efforts, and a reliance on reactive rather than preventive measures. Additionally, inconsistent equipment performance impacted product quality, creating variability that required additional inspections and rework.

Underlying Issues:

• Lack of a structured maintenance plan
• Limited operator involvement in basic machine care
• Inadequate tracking of equipment conditions and early warning signs

Universal Edge Services introduced Total Productive Maintenance (TPM) and trained operators in basic maintenance activities, enabling early detection of issues. A preventive maintenance schedule was established, supported by visual management tools for tracking tasks.  

Equipment downtime was reduced by 45%, leading to a significant increase in production uptime and an 18% rise in overall productivity. 

Tyre manufacturing is a multi-step process involving mixing, calendaring, extrusion, tire building, and curing. Each step needs precise handling to ensure material properties meet the required specifications. The manufacturer experienced high levels of material wastage, especially during the changeover between production runs, when leftover material and inefficient transitions contributed to scrap. This not only increased raw material costs but also posed environmental concerns. The issue was exacerbated by poorly defined setup procedures and a lack of standardization, which led to variability in changeover times and output.

Underlying Issues:

• Inefficient setup and changeover processes
• Lack of real-time tracking for material usage and scrap generation
• Insufficient training for operators to manage material transitions smoothly
• Inconsistent adherence to best practices, resulting in deviations and rework

We implemented Lean Six Sigma projects to analyze the production process and identify non-value-added activities. The team introduced a setup wheel system to optimize changeovers and reduce waste during material transitions.  

Material wastage was cut by 30%, leading to cost savings of 22% and improved sustainability metrics. The optimized process also enhanced product quality and reduced rework.

In the paint manufacturing process, consistency in batch production is critical to maintaining color and quality standards. The company faced challenges with variability in the formulation and mixing phases. Small deviations in raw material quality, temperature control, or mixing times led to color mismatches and inconsistencies in paint texture. This variability caused customer dissatisfaction, increased returns, and additional quality control checks. The issue was further complicated by frequent machine recalibrations and operator errors, which made it difficult to ensure uniformity across large production batches.

Underlying Issues:

• Lack of robust monitoring systems to ensure consistency during mixing
• Variability in the quality of raw materials and ineffective quality control at the start of production
• Insufficient training for operators on adherence to precise formulation procedures
• Dependence on manual processes without real-time feedback mechanisms 

Universal Edge Services implemented Statistical Process Control (SPC) to monitor and control key parameters during the formulation and mixing processes. A robust training program was also developed for operators to ensure adherence to standard operating procedures. 

Batch variability was reduced by 40%, enhancing product quality and consistency. This led to a 25% decrease in customer complaints and improved overall brand reputation.