This document outlines solutions to common pain areas and issues related to materials and processes. It proposes working with suppliers and internal teams to reduce rejections at receipt and during production. It also suggests conducting root cause analysis of field failures and process issues to improve reliability, productivity and reduce costs. Additionally, it recommends optimizing processes, materials selection and early vendor involvement to reduce development time and costs for new products and applications.

1. Materials Info : Your partners for Materials&Processes
Raghvendra Gopal

2. Your Pain Areas
1. Receipt stage:
Material not to spec
Process related issues
Surface protection
Other issues
Raghvendra Gopal

3. Our solutions :
Working with your suppliers to reduce rejections in the
incoming stage for materials/processes followed by
rejections at supplier factory , Thus increasing your
response time for new developments and reducing
development and supply costs.
Raghvendra Gopal

4. 2. Critical Field failure i.e IPTV and design validation
failures
Our solutions:
Working closely on your field failure/IPTV Data and
carry out root cause analysis with problem solving
tools alongwith internal teams to bring down IPTV,
thus improving reliability of the product and improving
brand image in case of IPTV and reducing the overall
development time
Raghvendra Gopal

5. 3. In process rejections:
Our solutions :
1.Working through your complete process flow
2.Finding out the specific root cause to bring down the
rejections , thus resulting in improved productivity,
reduction in cost associated with the rejections.
Raghvendra Gopal

6. 4. Low Process yield :
Our solutions :
1.Study of the complete manufacturing process at all
stages
2.Optimizing the process to improve yield.
Raghvendra Gopal

7. 5. High development time for new products:
Our solutions :
1.Study of the complete process for new project
introduction.
2.Working on all stages of new product development
3.Finding out the bottleneck areas
4.Plugging the same to reduce the Development time
and thus increasing response for new developments
Raghvendra Gopal

8. 6. High DMC ( Direct material cost) :
Our solutions :
1. Study of the complete design stages
2. Study the application of the part and associated
load/working stresses/environment.
3. Suggest optimization of part and alternate grade
/type materials to reduce cost.
Raghvendra Gopal

9. 7. High cost of Imported Raw
material/steel/components:
Our solutions:
1. Study the application in detail
2. Work with the steel mills/raw material
source/component manufacturer
Raghvendra Gopal

10. 8. Delay in response/developing export applications:
Our solutions:
1.Study of the raw material , standards and equivalent
2.Study of the whole manufacturing process spec and
sequence
Raghvendra Gopal

11. 9. Delay in taking up projects intensive to new
materials/processes/surface protection adding value
to end customer :
Our solutions:
1.Benchmarking for various materials and processes
2.Trend analysis for new developments in materials
and processes
3. Start pilot study /trials for the same
4. Project introduction
Raghvendra Gopal

12. 10.Lack of Early Vendor involvement:
Our solutions:
1. Involving your vendors in early stage of
development.
2. Working with them continuously to bring down
manufacturing process and material costs during
development
Raghvendra Gopal

13. 11.Weight above benchmark with low fuel efficiency:
Our solutions:
1.Study of benchmark vehicle
2.Alternate materials, constructions and design to bring
down the weight including design with Aluminium,
hybrid and plastic.
3.Working with internal teams for ride/handling and
durability aspect of proposed design till
implementation.
Raghvendra Gopal

14. Other Support Areas:
1.Working with internal project teams in the area of
QFD, DFMEA, Design for six sigma ,reliability, Lean
process .
2.Awareness trainings for Quality systems, DFMEA,
manufacturing process, materials technology, other
Quaity tools including problem solving both for the
organisation and the critical suppliers i.e development
partners.
3.Design validation right from data acquisition support,
understanding usage requirement, QFD, co ordination
with external test labs for design validation, materials
and process validation, dimensional and other tests.
Raghvendra Gopal