Embracing Lean Manufacturing: A Conversation with Steve Intagliata on the Unico System

A Journey Towards Efficiency and Excellence

For the past decade, the Unico System has been on a transformative journey toward lean manufacturing—one that has redefined efficiency, improved productivity, and reshaped company culture. At the heart of this evolution is Steve Intagliata, who recognized the inefficiencies of traditional batch-and-queue manufacturing and sought a better way forward.

“We were touching the product too many times,” Steve recalled. “It was inefficient, and we weren’t meeting our goals. The only way to improve was to adopt lean manufacturing.”

Finding the Right Advocate

Implementing lean principles wasn’t an overnight shift. It took years of searching before Steve found the perfect champion for this transformation—Ken Tharp, Unico’s plant manager.

Ken’s background in the military and his training in Japan, the birthplace of lean manufacturing, made him the ideal leader for the initiative. “He studied in Japan, learned the trade, and brought it back to the States,” Steve shared. “He worked with several large manufacturers but preferred small businesses—so when he found us, it was a perfect match.”

A Lean Approach to Manufacturing

Since embracing lean principles, Unico’s manufacturing process has undergone a complete overhaul. “We’ve drastically reduced the number of times we touch the product,” Steve explained. “Now, we cut on the laser today, form it today, and assemble it on Monday. The entire process flows seamlessly.”

This shift has led to remarkable improvements, with efficiency levels soaring beyond 90%. The streamlined approach minimizes waste, maximizes output, and ensures that production runs smoothly.

Cross-Training and Team Development

A key component of Unico’s lean strategy is employee cross-training. “Anyone on our assembly line can step into another role if needed,” Steve said. “If someone is out sick or on vacation, we can easily move people around. It keeps things running smoothly and makes the work more engaging for our team.”

This flexibility has not only improved efficiency but also fostered a more dynamic and empowered workforce. “People love goals,” Steve emphasized. “If you give them clear targets, they will achieve them.”

Lean Manufacturing in Modular Construction

Unico’s lean approach extends beyond the factory floor, especially when it comes to modular home construction. “In a modular factory, everything moves on a strict timeline,” Steve explained. “HVAC installation has to happen within a precise window. Our system allows us to provide pre-cut, pre-measured ductwork that fits perfectly, speeding up installation and reducing delays.”

By embracing lean manufacturing, Unico has positioned itself as a leader in efficiency, delivering high-quality products while reducing costs and time-to-market.

Building a Culture of Continuous Improvement

Beyond the tangible benefits of lean manufacturing, Unico has cultivated a workplace culture centered on communication, teamwork, and leadership. “Culture is key,” Steve stated. “If employees don’t know the company’s goals, they can’t work toward them. That’s why communication and servant leadership are at the core of our success.”

Steve makes it a priority to walk the factory floor multiple times a day, engaging with employees and gathering feedback. “If someone has an idea to improve efficiency, we discuss it. Can we implement it? Will it make us faster? These conversations drive continuous improvement.”

Leveraging Technology for Future Growth

As part of Unico’s lean journey, the company has also embraced technological advancements, including a transition to a Microsoft Dynamics ERP system.

“This system has been a game-changer,” Steve said. “It allows us to predict future demand and balance our inventory more effectively. Technology is a key part of lean manufacturing, and we’re always looking for ways to improve.”

Always Striving for More

Despite the incredible progress Unico has made, Steve remains focused on continuous improvement.“We’ve achieved a lot, but there’s always room to grow,” he said. “I never give full marks on a survey—because if you’re perfect, you have nowhere to improve.” With a relentless commitment to lean principles, technological innovation, and a strong workplace culture, Unico is setting new standards in manufacturing—one efficient step at a time.