Case Studies 

Revolutionizing Automotive Domain: The Two-Wheeler Electric Vehicles Revolution – Powering Ahead with Cutting-Edge Mechanical Parts 

DESIGN 

Case Study 1: Improving Frame Body Quality for Electric Vehicles

Challenge: A leading manufacturer of electric vehicles faced a quality control issue with frame body components, leading to high rejection rates and scrap losses.

Solution: Adhithya Innovations conducted a thorough analysis and implemented process improvements, resulting in:

Key Outcomes:

  • Significant cost savings
  • Zero scrap value
  • Zero-line stoppage
  • Improved quality

PRODUCT DEVELOPMENT

SUPPLIER SELECTION 

R

SUPPLIER QUALIFICATION 

Case Study 2: Reducing Battery Pack Rejection in Electric Vehicles

Background: A leading Electric Vehicle (EV) manufacturer aimed to improve the quality of their battery packs, Plastic Enclosures and reduce rejection rates.

Challenge: The company faced a battery pack rejection rate of 4%, resulting in significant costs and production delays.

Solution: Adhithya Innovations partnered with the company to implement a comprehensive quality control program, which included:

  • Manufacturing Process Audits, Supplier Selection and Supplier Qualification
  • Improved testing procedures
  • Revised supplier quality standards
  • Employee training and awareness programs

Results:

  • Battery pack rejection rate reduced from 4% to 1%
  • Significant cost savings
  • Improved production efficiency
  • Enhanced product quality and reliability

PRE-PRODUCTION VALIDATION

PRODUCTION PLANNING

U

INCOMING QUALITY CONTROL 

Case Study 3: PPAP for Electric Vehicle Batteries

Background: Leading EV manufacturer needed a PPAP for battery packs to ensure quality and reliability.

Challenge: Implementing a comprehensive PPAP meeting international standards and customer requirements.

Solution: Adhithya Innovations collaborated to develop and implement a customized PPAP, including:

  • Design and development reviews
  • Prototype testing and validation
  • Pre-production validation (PPV)
  • Process capability studies
  • Initial process capability approval
  • Qualified laboratory and testing facilities
  • Continuous monitoring and control

Results:

  • Successful PPAP implementation for electric vehicle batteries
  • Ensured compliance with international standards and customer requirements
  • Improved quality and reliability of battery packs
  • Enhanced customer satisfaction and trust
  • Reduced production costs and improved efficiency

PRODUCTION AND ASSEMBLY

Case Study 4: Production & Assembly in EVs

Challenge: Inefficient production & assembly processes in electric vehicle manufacturing.

Solution: Adhithya Innovations analyzed & optimized workflows, implemented lean techniques, automated assembly lines, enhanced quality control & trained personnel.

Results:

  • 30% reduced production time
  • 25% lower labor costs
  • 20% improved product quality

Best Practices: Continuously analyze & optimize processes, leverage automation & technology, enhance quality control & train personnel.

PACKAGING

SHIPPING 

Case Study 5: Packing & Shipping in EVs

Challenge: Inefficient processes damaged EV components, caused delays, and increased costs.

Solution: Customized packing, automation, optimized routes, and real-time tracking.

Results:

  • 40% less damage
  • 25% faster delivery
  • 15% lower costs
  • Happier customers

Transforming the Aerospace Industry: A Revolution in Customer Experience

Case Study 1: ROSI (Reporting of Safety Incidents) in Air Traffic Control
Client: Aerospace Customer, UAE
Background:
To establish data driven report aviation safety incidents and events, ensuring efficient data collection, analysis, and dissemination to stakeholders.
Objective:
Mentoring of ROSI (Reporting of Safety Incidents) process, to facilitate the reporting of safety incidents and events in the aviation sector.
Solution:
Adhithya Innovations mentored to increase the customer experience in ROSI, to enable:
  • Incident Reporting: Easy submission of safety incident reports by aviation professionals
  • Data Management: Analysis of reported incidents
  • Data Analytics: Identification of trends, patterns, and insights to inform safety improvements
  • Stakeholder Engagement: Automated notifications and reports to relevant authorities, airlines, and other stakeholders
Benefits:
  • Enhanced Safety: Improved incident reporting and analysis, leading to proactive safety measures
  • Increased Efficiency: Streamlined reporting process, reducing manual errors and time
  • Data-Driven Insights: Actionable intelligence and industry stakeholders to inform safety decisions
  • Compliance: Adherence to international safety reporting standards and regulations
Outcome:
ROSI has become the primary platform for reporting aviation safety incidents facilitating:
  • Increased reporting rates
  • Improved data quality
  • Enhanced safety awareness
  • Data driven decision making 
Service: Online Consulting
 
 
 
Case Study 2: Reducing Flight Delays through Data Analysis
Client: Aerospace Client, USA
 
Challenge:
  • Identify key variables contributing to flight delays from a large dataset.
Solution:
  • Our team applied Principal Component Analysis (PCA) to simplify the complex data set and determine the most significant factors causing flight delays.
Outcome:
  • By pinpointing the crucial variables, our client can now implement targeted improvements to minimize delays and enhance overall flight operations.
Service: Online Consulting
 

Focus on Bathroom Automation (Mechanical Design) – Adhithya Innovations As Catalyst For a Cleaner & Healthier World

 

Case Study 1: Complete Concept to Production (Mechanical Design) – Bathroom Automation – Revolutionizing Commode Servicing (Automatic Flushing System)

Problem Statement

  • Inefficient commode servicing processes, requiring complete removal and manual intervention, leading to increased downtime and maintenance costs.

Solution Overview

  • Design and integration of a modular front enclosure, enabling swift access, repair, and replacement of internal components, minimizing labor requirements and enhancing overall hygiene.

Key Benefits

  • Reduced Mean Time To Repair (MTTR)
  • Improved First-Time Fix Rate (FTFR)
  • Enhanced Customer Experience (CX)
  • Increased Operational Efficiency (OE)

Implementation Roadmap

  • Design For Manufacturability (DFM): Collaborative design and prototyping
  • Verification and Validation (V&V): Rigorous testing and quality assurance
  • Integration and Installation: Seamless deployment and commissioning
  • Training and Support: Comprehensive maintenance and troubleshooting guidance

Conclusion

  • Streamline bathroom automation servicing with a modular front enclosure, driving efficiency, productivity, and customer satisfaction.

Case Study 2: Value Engineering in Electronic Flushing System

Challenge

  • Complex design with many components
  • High material costs due to excessive weight

Solution

  • Simplified component architecture
  • Minimized part weight through material optimization

Results

  • 30% fewer components
  • 25% weight reduction
  • 20% cost savings

Methodology

  • Functional analysis
  • Design optimization
  • Material selection
  • DFMA implementation

Conclusion

  • Value engineering optimized the electronic flushing system, reducing complexity, weight, and costs while maintaining performance.