DESIGN 

MANUFACTURING PROCESS AUDIT

MANUFACTURING

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 the following:

• Manufacturing Process Audits at OEM, Tier 1 & Tier 2 and Supplier Qualification
• Monte Carlo Simulation for Geometric Dimensioning & Tolerancing in Design
• Manufacturing Datum analysis and implemented process improvements
• Improved testing procedures
• Revised supplier quality standards
• Employee training and awareness programs

Key Outcomes:

• 1.4 Crores cost savings
• 24% Defects to <1% 
• Zero-line stoppage
• Improved quality

PRODUCT DEVELOPMENT

MANUFACTURING PROCESS AUDIT & SUPPLIER SELECTION 

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

INCOMING QUALITY CONTROL 

Case Study 3: Reducing Battery Pack Rejections & Establishing A New Battery Line

Background: Leading EV manufacturer – Betteries failing in the market needed RCA and CAPA 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  RCA, including:

• Manufacturing Process Audits across OEM, Tier 1 & Tier 2
• Process Flow Diagram changed to suit IP67 requirtements
• Design and development reviews
• IP 67 Leakage Testing Machine Prototype testing and validation
• Pre-production validation (PPV)
• Facilitated to establish new battery line including IP67 Leakage testing machine & traceability
• Process capability studies
• Initial process capability approval
• Qualified laboratory and testing facilities
• Continuous monitoring and control

Results:

• The new Battery line produced zero defect Battery Pack
• 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

MANUFACTURING

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

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% Defect Reduction
• 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.