As India’s manufacturing sector accelerates toward global competitiveness, companies must balance scaling production with sustainability and efficiency. At Shiv Sagar Enterprise, we’ve embraced this challenge by integrating automation and the 5S workplace management system into our operations — not only to boost output, but to reduce waste, errors, and energy usage.
This blog explores how our commitment to smart systems and sustainable practices powers our growth — and delivers lasting value to clients.
Why Scaling Up Needs Smarter Systems
As we expanded our production capacity to over 40,000 plastic moulded and 5,000 rubber components daily, we recognized that simply adding machines wasn’t enough.
To truly scale:
- Processes must become repeatable and predictable
- Downtime must be eliminated or minimized
- Waste must be reduced
- Operators must work in safe, organized environments
This led us to implement two core strategies: automation in key production stages and the 5S methodology for shop floor excellence.
The Role of Automation in Our Growth
Automation helps us improve precision, speed, and consistency — especially as batch sizes and client expectations increase.
🔹 Where We Use Automation:
- Injection Moulding Cycle Optimization: Automated sensors and controllers ensure correct temperature, pressure, and injection timing
- Robotic Part Pickers: Reduce human handling, speeding up cooling and packing
- Material Feeding Systems: Maintain consistent resin flow to machines
- Batch Traceability Software: Automates data logging and quality checks
✅ Impact: Less human error, tighter tolerances, and a 30% boost in output efficiency on select product lines.
Implementing 5S for Workplace Efficiency
The 5S System (Sort, Set in Order, Shine, Standardize, Sustain) is the foundation of lean manufacturing. We adopted it across our factory to:
- Eliminate clutter and confusion
- Ensure tool and part availability at the point of use
- Maintain cleanliness to reduce wear and product contamination
- Standardize machine maintenance and inspection
Our 5S Initiatives Include:
- Labeled shadow boards for tools
- Part-specific trays and bins to avoid mix-ups
- Daily cleaning schedules and visual audits
- Standardized SOPs for mould setup and teardown
- Regular training to reinforce best practices
✅ Result: Faster turnaround times, improved safety, and cleaner, more organized workstations — every shift, every day.
Efficiency = Sustainability
One of the most important side effects of automation and 5S? Sustainability.
Through these systems, we’ve achieved:
- Reduced raw material wastage through process consistency
- Lower power usage per part due to efficient machine cycles
- Reduced rejects and rework rates
- Minimal packaging errors and logistics waste
We also reuse excess material wherever feasible and follow waste segregation and recycling policies to ensure environmentally responsible productions.
This aligns with our long-term vision of being a low-impact, high-output manufacturer serving global markets.
From Local to Global: Sustainable Growth in Action
Thanks to these improvements, Shiv Sagar Enterprise has been able to:
- Expand our client base across Gujarat, Maharashtra, NCR, and South India
- Deliver consistent quality for export orders
- Serve high-volume OEM clients with zero compromise on timelines or quality
- Prepare for ISO certification and international compliance audits
We’re not just growing — we’re growing intelligently and responsibly.
Conclusion: Building a Better Factory for the Future
At Shiv Sagar Enterprise, we believe that efficient manufacturing is sustainable manufacturing. By integrating automation technologies and embedding the principles of 5S into our daily operations, we’ve created a culture of continuous improvement — one that benefits our team, our clients, and the planet.
Whether you’re an OEM looking for high-volume moulded components or a product developer seeking reliability and responsiveness, our systems are built to serve you better — today and in the years ahead.
📩 Contact us today to learn how our sustainable manufacturing approach can bring value, speed, and quality to your next project.
