Author: Audree Grubesic
Published: Jul 3, 2025
Updated: Jan 22
Unico System has spent the past decade moving from batch-and-queue manufacturing to lean manufacturing. Steve Intagliata said the old process involved touching the product too many times and did not meet company goals.
He said the change improved efficiency, productivity, and company culture.
Steve said the key advocate for lean manufacturing was Ken Tharp, Unico’s plant manager.
He described Tharp as someone with military experience and training in Japan, which Steve identified as the birthplace of lean manufacturing. Steve said Tharp preferred small businesses and was a strong match for Unico.
Unico reduced the number of times it handles each product.
Steve said the streamlined process pushed efficiency levels beyond 90%.
Unico uses cross-training on its assembly line.
Steve said Unico’s system supports modular home construction, where HVAC installation must happen within a strict timeline.
The company provides pre-cut, pre-measured ductwork that fits the job and helps speed installation while reducing delays.
Steve said culture is central to success.
He said he walks the factory floor multiple times a day to gather feedback and discuss improvement ideas.
Unico has adopted a Microsoft Dynamics ERP system.
Steve said the system helps predict future demand and manage inventory more effectively. He described technology as an important part of lean manufacturing.
Steve said Unico has achieved a lot but still has room to grow. He said he never gives full marks on a survey because perfection leaves no room for improvement.