MANUFACTURING COST & OPERATIONAL EXCELLENCE
Turn operational gaps
into measurable savings.
Reduce cost. Improve productivity. Optimize energy, manpower and yield.
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Higher
Productivity
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Resource
Optimization
groups
Sustainable
Growth
PEOPLE | PROCESSES | PERFORMANCE | A STRONGER TOMORROW
₹450 Cr+
CUMULATIVE SAVINGS DELIVERED
400+
IMPROVEMENT PROJECTS
What We Solve
Critical Manufacturing Challenges We Optimize
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Reduce Manufacturing Cost
Comprehensive cost-reduction across RM/PM, manpower, utilities, and process scrap.
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Improve Productivity & Capacity
Debottlenecking, line balancing, and cycle-time optimization to expand plant throughput.
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Optimize Power, Fuel & Utilities
Benchmark Specific Energy Consumption (SEC), steam, boiler, and compressed air systems.
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Reduce RM/PM & Process Wastage
Material mass-balance reconciliation, BOM variance control, and rework elimination.
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Improve Quality, Yield & TAT
Cp/Cpk capability improvement, defect reduction, and queue-time compression across the floor.
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Release Working Capital
WIP reduction, raw material buffer optimization, and dispatch schedule adherence.
Up to 30%
Productivity / Labour
Workload study, line balancing & standard work.
Up to 30%
Power & Fuel
Specific energy consumption (SEC) benchmarking.
Up to 25%
RM/PM Wastage
Material balance & loss-tree elimination.
Up to 40%
Turnaround-Time (TAT)
Queue reduction & bottleneck debottlenecking.
Strategic Transformation Levers
MANUFACTURING PROFITABILITY
• RM/PM Cost Optimization
• Process Yield Improvement
• Scrap & Loss Elimination
• Workload & Line Balancing
• Skill Matrix & Multi-skilling
• Optimum Labour Deployment
• OEE & Availability Uplift
• Capacity Debottlenecking
• Breakdown & Changeover MTTR
• Cycle Time Compression
• Visual Standard Operating Work
• In-process Quality Controls
• Specific Energy Norms (SEC)
• Fuel & Steam Efficiency
• Compressed Air & Utilities
• Raw Material Buffer Control
• WIP & Finished Goods TAT
• S&OP Planning Discipline
Engagement Lifecycle
Our Implementation Journey
STAGE 01
Diagnose
3-5 day shop floor assessment.
STAGE 02
Baseline
Agreed financial & operating baseline.
STAGE 03
Analyze
Loss-tree and root-cause analysis.
STAGE 04
Improve
Low-cost automation & balancing.
STAGE 05
Implement
Hands-on execution on the Gemba.
STAGE 06
Control & Sustain
SOPs, daily reviews & audit controls.
Specialized Domains
Manufacturing Industries Served
Food & Beverage
Confectionery & Bakery
Distillery & Brewery
Pharmaceuticals
Printing, Packaging & Corrugation
Steel & Metal Processing
FIBC & Technical Textiles
Chemicals, Fertilizers & Edible Oil
Explore Sector Challenges & Addressed KPIs arrow_forward
Portfolio Credibility
Selected Clients / Organizations Served
Prestige Group
Mahakali Foods
Shivangi Rolling Mill
H D Wires
Dynamech Engineers
Pratibha Syntax
Commercial Syn Bags
Shree Tirupati Balaji
Hindustan Phosphates
Mahadhan Agro
Prataap Snacks
Mysore Deep (MDPH)
Leadership & Expertise
Pankaj Goyal
Managing Director | Lean Six Sigma Black Belt | Lean Expert
27+ Years of Manufacturing & Operational Excellence Experience
His professional experience includes leadership and improvement roles with renowned organizations including Mars Inc. Dubai, Parle Agro, A.V. Thomas I.P., Dorf Ketal and Godrej Agrovet. Through UB Excellence, he has supported manufacturing organizations across multiple industry sectors to deliver measurable, sustained financial and operational improvements.
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Take The Next Step
Identify Your Plant's Cost & Capacity Potential
Our 3 to 5-day on-site diagnostic evaluates material, energy, labor, and line bottlenecks to deliver a prioritized, financially quantified roadmap.
*Target ROI ≥ 3× Consulting Fee. Financial impact is jointly validated with client management. Actual results depend on implementation, operating conditions and the agreed baseline.
