Streamlining Production and Boosting Efficiency: How EML Helped Unique Diecasting Automate Operations and Improve Clarity

Background

Unique Diecasting Products Pvt Ltd, a leading manufacturer of aluminum die-cast components, has been a key player in the pressure diecasting and engineering industry for over 22 years. Based in Navi Mumbai, the company operates out of a 10,000 sq ft facility, producing precision components for both Indian and overseas markets. Despite their experience, manual processes were hampering production efficiency and leading to delays in reporting and decision-making.

The Problem

Like many manufacturers, Unique Diecasting faced operational bottlenecks due to the manual handling of production data on spreadsheets. While this system worked, it came with a series of challenges. The data entry process was cumbersome, often requiring duplicate entries, which increased the risk of manual errors. Generating reports—such as worker incentives and production status—was time-consuming and typically only completed at the end of each month. This led to delays in responding to customer queries, a lack of real-time production insights, and reduced operational efficiency.

Solution Offered

To address these issues, EML developed a comprehensive production data management system tailored to the needs of Unique Diecasting. The solution included creating master records for various key production elements—customers, components, workers, operations, raw materials, and rejection rates. User-friendly forms were designed with built-in drop-down menus and auto-fill features to capture work orders and daily production activities. A dedicated form was also introduced for recording rejection quantities.

EML also developed a real-time incentive report, eliminating the need for end-of-month calculations, and an automated Production Tracker Dashboard that displayed the status of all production work orders and month-to-date (MTD) production metrics.

Implementation Process

EML implemented the Shop Floor Production Reporting system in a phased manner. The initial phase focused on replacing manual line reporting and automating incentive calculations. However, the early stages were met with challenges—users struggled with the unfamiliar system and system setup issues. EML and Unique Diecasting worked closely together to troubleshoot these problems, ensuring swift issue resolution and smooth integration.

The second phase involved adding complexities such as work orders, rejections, and end-to-end process mapping. This expansion also introduced some instability, but through ongoing collaboration and persistence, the system eventually stabilized. Unique Diecasting's team played a key role in the successful implementation, driving the project forward with determination, while EML remained responsive and adaptive throughout.

Results and Benefits

The new system has transformed Unique Diecasting’s production process, delivering significant improvements in efficiency and clarity. Key benefits include:

Time Savings: Data entry became more streamlined, significantly reducing the time required to input and manage information.
Real-Time Insights: The automated dashboard provided a live overview of production statuses, giving the team full visibility into the progress of work orders and shop floor activities.
Incentive Automation: Worker incentives could now be calculated in real-time, saving valuable time and eliminating the need for month-end manual reporting.
Enhanced Customer Response: With clearer insights into production workflows, Unique Diecasting could confidently provide customers with accurate and timely updates on their orders.
Reduction in Order Delays: Increased visibility into order statuses helped reduce production delays, further boosting customer satisfaction.

By automating key processes and enhancing visibility, EML’s solution enabled Unique Diecasting to optimize their operations and scale efficiently, ensuring they could continue to deliver high-quality products on time, every time.