UTL Solar is a rapidly growing renewable energy company with manufacturing and assembly operations in Solan, Himachal Pradesh. To support scalable and sustainable growth across a workforce of 600+ employees, UTL partnered with PX Consulting to implement a plant-wide Operational Excellence program that strengthened standardization, execution discipline, and people capability.
UTL’s rapid workforce expansion created operational strain before processes and routines were fully institutionalized. Productivity varied significantly across departments due to inconsistent methods and unclear performance ownership. Strategy-to-execution alignment was limited, resulting in gaps between leadership priorities and shop-floor actions. In addition, inconsistent practices increased safety and quality risks—creating exposure during audits and while scaling capacity.
PX Consulting designed and executed a structured, phased transformation over nine months focused on stabilizing operations, aligning performance management, and enabling people to sustain improvements.
The engagement began with a baseline assessment of operational performance and risk. This included workforce productivity analysis to identify variability drivers, a process maturity assessment to map current-state practices, and safety and quality audits to surface compliance gaps and standardization needs.
The next phase focused on building clarity, consistency, and execution rhythm. Role clarity and KPI deployment ensured measurable ownership across functions. SOPs and work instructions were rolled out to reduce variation and improve training effectiveness. Visual management and structured performance reviews were introduced to make targets, gaps, and actions visible—improving focus and accountability at every level.
To sustain the gains, UTL invested in capability building across the organization. Lean awareness programs created a shared language of waste elimination and standard work. Frontline leadership development strengthened supervisors’ ability to manage performance, coach teams, and resolve issues. A continuous improvement roadmap was built to prioritize initiatives and maintain momentum beyond the program.
The overall solution included a plant-wide Operational Excellence model, KPI cascading from leadership to shop-floor, a structured daily review and escalation mechanism to accelerate issue resolution, and an integrated safety, quality, and productivity framework to ensure balanced performance.
The program delivered tangible improvements across productivity, coordination, and compliance. UTL achieved a 10–12% improvement in labor productivity, supported by clearer roles, standardized work, and stronger review routines. Cross-functional coordination improved through aligned KPIs and structured escalation.
Safety compliance and audit scores increased due to consistent practices and integrated governance. Most importantly, the organization built a scalable operating system—preparing UTL Solar for future expansion with stronger execution discipline and continuous improvement capability.