The leading exporter of HVAC electrical motors from India
Overcome the commodity price increase of Copper by 250%, making end product unviable
Applied basic principles of Physics and Electrical Engineering to evaluate the use of alternate materials
Overcame skepticism of “industry experts” and formed a core team of engineers to follow through on the self-belief that it could be done
Leveraged six sigma problem-solving techniques to overcome technical challenges related to filling 33% more of the alternate material Aluminium in the same slots designed for Copper
Involved material supplier to develop alternate and robust connection techniques for multi-speed operations
Used Pareto analysis (80-20 rule) to pick key models to implement design and material change in 45 days
Improved Operating Margin by 10% points from the standard (would have been negative if the original material was used)
Gained, market share at key customers from 60 to 100%, & eliminated competition who were asking for the price increase.
Created a new industry standard that took competition 3 years to adopt…maintained Single source status
Today, aluminum wound motors are 70 % of the market.
