Universal Solar Products, Inc.

Universal Solar Products manufactures solar water heaters and water tanks for the residential and institutional markets in Puerto Rico. Their production facilities are located in Toa Baja, Puerto Rico. In addition to their administrative and sales personnel, they have 40 employees in production activities. Quality, labor cost improvements and effective materials management are essential for remaining competitive in this highly-competitive market.

The supply chain disruptions caused by the COVID-19 pandemic were a real challenge due to long lead unique items used by the company. Unique items shortages were affecting their ability to serve the customers. At the same time, the plant manager, who also managed the materials and inventory control function, resigned and left the company. The general production foreman also presented his resignation. Finding suitable replacements for these two key operational resources was a real challenge and, also, critical for satisfying the plant’s current level of customer orders and preparing for the projected sales increase as the pandemic restrictions were relieved.