About the Client
Lucas TVS is a pioneering name in India’s automotive electrical and electronics industry, with a legacy spanning over 60 years. A key player in auto components manufacturing, the company supplies starter motors, alternators, wiper systems, and other critical components to leading automobile brands in India and global markets. With multiple state-of-the-art manufacturing facilities and a strong focus on R&D and innovation, Lucas TVS is at the forefront of next-gen automotive technology, including EV components and advanced power solutions. The company’s commitment to quality, reliability, and continuous improvement has made it a preferred partner for top OEMs in the automotive, industrial, and off-highway sectors.
Workshop Objective
The objective of the workshop was to deepen participants’ understanding of Design for Manufacturing (DFM) and Design for Assembly (DFA) principles specifically for automotive components such as starter motors and alternators. The program focused on design optimization for cost, quality, and manufacturability, enabling engineering, R&D, and operations teams to collaborate more effectively and bring innovations from concept to shop floor with minimal friction.
Workshop Summary
This highly interactive, instructor-led workshop offered a structured deep dive into DFM and DFA strategies, blending foundational theory with practical, case-based learning. The training emphasized real-world applications and live evaluation of in-house starter motor and alternator components.
Key highlights included:
- Comparative analysis of conventional vs. DFM/DFA-optimized designs
- Hands-on redesign exercises for part simplification, cost reduction, and ease of assembly
- Exploration of materials, tolerance stack-up, process capability, and modular design principles
- Team-based activities to identify manufacturing bottlenecks and assembly challenges
- Use of live components to conduct design audits and improvement proposals
The session concluded with an action planning segment, equipping participants with the tools and mindset to integrate DFM/DFA principles into ongoing product development cycles.
Workshop Details
- Mode: On-Site
- Audience: EV Engineering, R&D, Product Development, and Plant Operations Teams
- Batch Size: 13 Participants
- Duration: 1-day Workshop
- Customized Training Modules
- Certificates for all participants
Trainer Profile
- An Automotive R&D and Design Optimization Specialist with 33+ years of industry experience.
- Expert in electrical and electronics systems, VFD/servo/PLC applications, and embedded automotive controllers.
- Proven track record in reducing motor noise, optimizing hydraulic systems, and building test rigs for OEM applications.
- He has trained professionals across automotive and industrial domains in DFM/DFA, electronics, solar systems, and actuator-driven controls.
