NPD PROCEDURE

ENQUIRY TRIAL PRODUCT

• Work with plant team ANNOUNCEMENT/DOCUMENTATION
for product
Receiving enquiry development
from market with or
• Give feedback to the
without specs
customer.
• Communicate new
product/proceCSSto the
concerned department
Initial trial by Sample or and record all related
Analysis of product Ask Team for selecting Max. 2 Lots only. document
feasibility & potential sample order
Align CIVs of
the m/c with
NO YES the product

Checking specs. If
within manufacturing
limits, possibility to
develop by improving Review and verify the Take trail of 6 document the
m/c & share with plants output product Based on more lots, and new product
out put future action then 10 more and
decision is taken. lot in loop proceCSSin
quality plan
and online
ERP system
Evaluate
Check if
Regret the product can
Not product Ok
trial
product to be made with
interplant
Ok result at
customer customer
proceCSScom end.
bination
ON SUCCESSFUL TRIAL
Integrity Commitment Passion Seamlessness Speed 1
Highlights

• New Product development: Transformer Winding, Jio structural components for 5G etc.
• New Customer added: Onboarded 36 new customers across key segments.
• Customer complaint closed: 117 out of 131 with 0.41% return in plants
• Upcoming development: fuel jel box , auto parts (Arihanta Metal), Cable wrap(Apar& others),
watch brand, Roll bond etc
• Business in pipeline : Legrand, Veer O metal , TRANSFIX INDIA Pvt Ltd ,MSS India Pvt Ltd,
APERAM ALLOYS INDIA PVT. LTD,Toshiba , Kamath Transformer, Synergy & Eletromill etc
• Process Improvement: R&D: Higher Elongation in AA3105, Arbor mark toolkit, Airbag packing
delivery for critical customer, case study for coil storage
New product developments and its application;

Product Application Prospect/Customer Current Status

Development of transformer winding quality coils Toshiba(1*640) , Kamath Transformer, Synergy &
AA1060-O –Coil 1. Current supply:
at Taloja with an annual potential of 1800MTPA. Eletromill.

Major challenge Property Benefit

High Electrical
Minimizes energy loCSSin
Conductivity (~61%
windings
IACS)
1. Edge burr
Good Thermal Helps in better heat
Conductivity dissipation
2. Oil free sliting
Corrosion Ensures longevity in oil-
Resistance immersed applications
3. Wrinkling / Buckling
Ductility in O Allows easy shaping and
4. Build up Temper winding
Reduces overall transformer
5. Electrical Conductivity<60 IACS Lightweight
weight

Cheaper than copper for the

Cost-Effective
same volume
6. Price (Jindal already supplying same product)
New product developments and its application;

Product Application Prospect/Customer Current Status

Investment by Jio and Airtel
on internet infrastructure
resulted in increased 1 Series
AA1050- O-1.00X315 mm coil Mehra Metal , Neuman
business for structural
(Reliance Jio & Airtel) , Nash 1. Current supply:
components for 5G and fiber
Industries & veer-o-metal
networks. with an annual
potential of 1800MTPA.
.

Heat Sink Air Fibre Dish

NPD/Query and its application;

Product Application Prospect/Customer Current Status

AA1100 H14 0.8/1 *1200 Will use in AC Ducting line Harsha Vardhan Air Conditioning
Order taken 30 T
mm (Government project) Engineers Pvt. Ltd

Challenge Faced:
1. High potential but very slow response
2. Quote for Government & private project
3. No one point contact.
New product developments and its application;

Product Application Prospect/Customer Current Status

Small containers for medical

AA1200 H18 0.3 mm purposes-(avg 3 T/month Navnidhi Containers, Palgarh 1. Current supply:

target)

Challenge faced :
1. Different samples tried and figure out cracking.
2. Customer die tolerance was very tight and fine
grinding was done for it. Advice to use the
lubrication while punching on samples.
3. An External small furnace use for partial ANL
sample.
4. Later use of AA1200 , H14 0.3 mm. found ok to
run
New product developments and its application;

Product Application Prospect/Customer Current Status

Washer and gasket

AA1050 H14 & AA1200 H14 Bright Auto [Link],
applications-(Avg 4T/per Sample run ok
2mm Chennai
month target)

Gasket
New product developments and its application;

Product Application Prospect/Customer Current Status

AA8011-H14 -0.47*48 mm Besmak Component,Kancheepuram,

No Current Requirement
india
Nasal Spray Pump- 0.3 T/M

Challenge faced :
4-5 different A4 samples A4 size sent to Customer,
trail ok but after Customer did not give positive
response regarding order booking
New product developments and its application;

Product Application Prospect/Customer Current Status

1. initial A4 sample was not performed due

Aluminium strip for on/off to short size
AA3003 H18 -0.8/0.7 mm Havells India 2nd times sample given but not performed as
switch per requirement & melt, this NPD dropped

Challenge faced :

1. The strip deformed, wear out, or lose contact pressure over

time.
2. Sample follow up with plant
3. When trail taken & strip used in a press-contact or toggle
mechanism, it did not return to original shape after
multiple time on/off condition, reducing switch
effectiveness.
New product developments and its application; in pipeline

Product Application Prospect/Customer Current Status

AA1100-H14-2500-1250-1.5 CLOUDWAVE TECHNOLOGIES

PRIVATE LIMITED

Challenge faced :
1. Both side lamination(70 micorn) required but
convicted Customer to take one side masking.
2. Scratch marks, rolling marks, footprint and
abrasions are visible on all of the inspected
sheets.
3. Delay in delivery
4. Customer rejected material as we could service as
per promised.
New product developments and its application;

Product Application Prospect/Customer Current Status

AA3003 -O
0.2 (+.012)* 53/70 mm (+/-0.0.15)
0.3 (+.014)* 81/105 mm (+/-0.0.15) plant visiting for Customer was arranged for
0.6 (+.018)* 130 mm (+/-0.0.15) Viega confidence, but plant final decision was not
taking this NPD due to tight tolerance.

use for Multilayer Pipe

Challenge faced :
1. Very tight tolerance for thickness,
2. for trail lot 0.2 mm (+0.020 tol)*53/70 mm(+/- 0.5
Tol) agreed for both side.
3. Customer visited at Taloja site & get insight
regarding the product quality
4. Due to order booked qty was 200 kg for trail, plant
asked for min . 3 T MOQ.
NPD & Querry and its application;

Product Application Prospect Current Status

Few Samples trail taken, found ok,

later asked for 100 kg in each size,
AA1050 H22
HSRP coils used for number plates E-cartes: 2-3 T/M rejected due to order qty low; will
1*46/101 try to convinced for 1.2-15 min
order

AA1100 H14
Samples export for trail purpose(100pics each UAE & Saudi based
(0.5,0.6,0.7,.0.8,1 Sample sent as per planned
gauge, plain and stucco) trader : 200 T/yr
mm)

As per Customer he was facing

scratches in H14 (degreasing) so
AA1050 H24 1.5 It is regular order AA1050 H14 Veer O metal/ we planned to give order in H24
from HKD

1. 1st trail lot given- oil stain

AA1050-O Alloy observed , partial rejection
Roll bond (Heat Exchangers) BMR Supa ALUMINIUM SHEET 1.5MMX1085MM W(ALLOY:1050)

1.5*1065 mm 2. 2nd trail lot sent , waiting for

Lot Details

Supplier Name Hindalco

Material
08-03-2024
Received on

Lot Qty 7230 KG Observed an oil mark at the corner of the sheet

Invoice No MHTLJ2310007784 Roll Identification Tag

Material Code 10002064

ALUMINIUM SHEET
Material
1.5MMX1085MM
Description
W(ALLOY:1050
Until now, such an issue
has been observed in one
Defective Qty
roll, while the remaining Evidence Video Clip

response.
three are on hold.

Defect Observed an oil mark at

Description the corner of the sheet

Quality First! Quality Must!! BMR HVAC Limited, Pune

In Pipeline: NPD & Querry and its application;

Product Application Prospect Current Status

1. Trail lots were rejected due to

coil ID 6 inch required, working
AA1060-O-0-50-0.5- Cable Wrap Apar Industries, Umargav
for alternative solution (feasibility
at outside inside of plant)

Req: Pb-0.009 mm in sheet, trail

AA1200 H14
Exporting for Auto parts, defense -9T, USA Arihanta Metal sheet ok but Pb% is big issue, to
1.5*1219 mm
work with HIC and plants

Suggested BB590 – 4 mm for

AA1060- 3.5 mm Electrical Application -20 MT/M Legrand trail. sample will likely be
dispatched on 31st May 25

Sample collected and testing

PO Rathi Chemical [Link],
AA1050-0.3 mm For fuel jel box done, AA8011 H14 -0.17 A4 size
New Delhi
sample provided for trail
Pipeline : New product developments and its application;

Product Application Prospect Current Status

1060-O-1*1000
Technical discussion done,
mm transformer stock TRANSFIX INDIA Pvt Ltd
awaiting for order

AA1060, AA1050,
AA1070, AA1350 Awaiting order, as Customer
Electrical component MSS India Pvt Ltd-
990(L)*520(W)*9 query for trail sample
0(H) mm
Al 3103 7.5 360
Temper O Al 110 APERAM ALLOYS INDIA
No order given yet
0.51 360 Temper PVT. LTD/innovative clad
O
In Pipeline: NPD & Querry and its application;

Product Application Prospect Current Status

chengfeng

Tmindad Al

1. AA3003 is ok for us , awaiting

AA3003 h14 response from Customer and
For Apple brand watch and other accessory use Salcomp
2*194 Hard alloy team as it is a joint
project

AA1050-O
Details share with Aditya FRP, will
0.35T x 81 mm & Cable wrap LS cable
take time to setup
0.36T x 46 mm
Pipeline : New product developments and its application;

Speacility Rejections FY 24-25

70000 0.70%

60000 58039 0.61% 0.60%

Closed % open
Complaints Rejection claim complaint open complaint complaint
50000 0.50%

40000 0.41% 0.40% Total 131 236.83 117 14 10.69

0.38%

30000 0.29% 0.30%

HKD 7 25.06 5 2 28.57
0.25%
20000
20000 0.20%
15000 15000
BLR 39 91.77 34 5 12.82
10000
10000 0.10%

TLJ 47 43.85 43 4 8.51

0 0.00%
Total HKD RKT BLR TLJ

Supplied rejection accepted by plant in T current rejection RKT 37 76.15 35 2 5.41

Opportunities to Improve
[Link] Flow Chart for Complaint & Clouser Responsibility
Complaint recived (with Invoice, date, pics , video and Basic defect
1 TM,CSS,TR
cataterization
2 Complaint analysis TR
3 Complaint lodge TR
4 Complaint detail share with concern plant TR
5 Visiting plan & feed back form share with Customer TR/TM
6 Trails for improveement at Customer end TR
7 Final rejection qty to be share with plant with address TR

8 Details of Truck to be share with Customer for rejection & follow Up TR

9 conformation of reejction recived at plant TR/Plant

10 RMA order Booking CSS
11 Credit note to be share with TM and Customer TR/plant
12 Put RMA order detail in CX portal & close the complaint TR
13 Follow up for Corrective Action plan & validation TR
Customer Complaint highlights:
S.N Customer Case Description Plant Possible Cause Improvement Effect

check other
Wooden Plank thickness Customer if facing
1. Pallet plank very thin
1 Tamilnad Pallet bending issue BLR increased, runner same issue after
2. Transportation issue
modified pallet modification
found ok

1. Wrong pallet loading

practice similar complaint
CHQ sheet bending 2. Mishandled/broken Loading Practice was was not coming
2 Akash RKT
issue during shift improved again for pallet
3. Broken/bent pallet loading issue
joints

1. Alloy & temper 1. No rejection as

Cracks were observed
confirmed order was correctly
in the coil supplied as
1. Wrong spec/material 2. Recommended H14 delivered
per AA1200-O,
3 Sun Led TLJ 2. Semi-skilled for 90° bends 2. Recommended
0.3×213 mm while
manpower 3. Highlighted H14 for 90° bends
operation at
competitor sharing for future for
customer`s end.
wrong TC prevent such case
Customer Complaint highlights:
Case
S.N Customer
Description
Plant Possible Cause Improvement Effect
1. Few rolls like groove
table and turn table rolls 1. Buffing done to All
having metal sticking and turn table roll as well as
White Spot in that metal sticking stuck to groove table No similar
4 Innovative CLAD TLJ
Coil on to the surface of coil 2. Groove table ovality complaints Customer Voice/
Problem Definition
White spots in coil
CAPA for White spot in coil– Innovative CLAD

Photograph Containment/ Salvaging

Action/Correction
Lot No. 23HRML250730 and other
(The final rejection Quantity of

2. Detection miss due to removed by grinding.

aluminium is 15612KG

Findings and Root Cause Corrective Action Preventive Action for other Sustenance Through
Short Term/Long Areas - Short term/Long Term (Mention the Doc
Term reference)

unable to check HRC

Occurance Few rolls like groove table and turn table Buffing done to All Groove table ovality removed by
rolls having metal sticking and that metal turn table roll as well grinding.
sticking stuck on to the surface of coil as to groove table

Detection Miss Detection miss due to unable to check HRC

surface.
Groove table roll which

surface.
found oval.

1. Shared visiting report

with posibble cause & No further
Laxmi Machine Dents, 1. Line defects
5 RKT action plant with plant complaint since
Work Scratches 2. Pallet/transport issues CUSTOMER VISIT REPORT

2. Advised record- last 1 year

Visiting company/Site: Laxmi Machine works, Coimbatore Date: 15-05-24
Attendance:
HINDALCO: Mr. Hemant Chawla

Laxmi Machine Works: Mr. Prabhu

Concern Discussion: Regarding the Accumulated rejection of 4.5 T approx. due to scratches,
Dent, Impression, ILF, roll stop marks etc in Hindalco Materials
Visiting at Shop Floor:

Issue observati ons.

1. Customer facing heavy rejecti on due to dent, roll stop marks, scratches.
2. The sheet with masking were taken directly to 2ndry Customer (3 rd party) for processing.
Here the sheets inspecti ons and segregati on process done. The operator carefully checks
all sheets before processing (with masking) as top and bottom both surfaces are criti cal
for fi nal product.
3. Roll stops., Dent, scratches were identi fying from input, pallets packing, and other things
were cross checked, found ok.
4. Each pallet at least 2-3 sheets from top and bottom were rejected for scratches, dents,
packing material impression.
5. LMW did not have records of lots/invoice in which sheets were rejected, requested to do

keeping
for future reference.
6. In accumulated rejecti on: 10 sheets were checked; some dents were observed from
length edge to 227 mm in line (from width edge side-around 130 mm). Which seem
while stacking it was generati ng some dents. Please check pics.

Laxmi is taking Material from us for making texti le machinery

since more than a decade and we sti ll did not have control over
dent/scratches issue for defects control, it is advice to take care at
exit side (while stacking the sheets),
please make checklist to check Rolls stop, Dents, scratches,
abnormal impression mark & separate the such sheets. For top and
bottom we found some pallet impression & sheets got rejected,
please take protecti ve layers covering for that.

1. Sample checked for

ANL/softness
AA3003-O- 1. Wrong material
2. Verified alloy and No rejection due
6 Industrial Metal 0.8mm RKT 2. Wrong die setting
temper to cracking
Cracking Issue 3. Semi-skilled person
3. Operator run with
lubrication – successful
Customer Complaint highlights:
Case
S.N Customer Plant Possible Cause Improvement Effect
Description Pic/doc
1. Case study for other
Asiatic Paper 1. >12% moisture in paper 1. Instructed customer on
Customer also for
Electrical & Stacking 2. Glue in stacker storage
7 HKD storage
Switchgear Pvt. Issue / 3. Rain ingress at plant 2. Shared storage/pallet
[Link] rejection in
Ltd. Bhiwadi Corrosion 4. Transport/storage issue protection guidance
incoming materail

Found missing airbag caused

1. Transport issue [Link] the transport
Coil Handling rejection; advised streamlined
2. Customer handling issue damaging issue
8 Chengfeng Damage / TLJ airbag packing
3. Improper [Link] internal NC
Packing Tear also, advice Customer to safely
loading/unloading due to strorage issue
store coils
1. Indentify critical
Drawing 1. Strip 183.5 mm, Die 186.5
1. Wrong spec parameter wrt to
Issue in mm, min. run 184 mm – issue
Holonix – 2. Semi-skilled manpower customer to run
9 AA1060-O TLJ due to holding support
Hardware 3. Wrong material product
(0.25×184 2. 2. Suggested trials with lower
4. Die setting incorrect 2. No rejections
mm) pin dia
accpeted
1. Alloy & temper confirmed 1. No rejection as order
Cracking at 2. Recommended H14 for 90° was correctly delivered
1. Wrong spec/material
10 Vishwa Buses 90° (AA8011 RKT bends 2. Recommended H14
2. Semi-skilled manpower
H18, 2 mm) 3. Highlighted competitor for 90° bends for future
sharing wrong TC for prevent such case
Customer Complaint highlights :
S.N Customer Case Description Plant Possible Cause Improvement Effect Pic/doc
[Link] critical
[Link] width issue;
parameter wrt to
Edge Gap Issue 1. High lateral curve 2. will book order in revised
11 IMC BLR customer to run
in GR Infra 2. Lot width mismatch spec and tolerance for same
product
application
2. Learning from failure.
[Link] critical
1. Visited customer; parameter wrt to
Spun Spun Tech – 1. Width issue
12 BLR 2. Shared revised specs & customer to run
Tech(MLTC) Shorter Width 2. Cutting process change
tolerance with part IDs product
2. Learning from failure.
[Link] of this particular
coil may not be guided to
the mandrel groove
[Link] end of the coil to be
equally at both side,
feed at mandrel groove
causing Crease formation 1. Educate the
properly.
on the subsequent layer Customer for right
2. VOC/OPL shared to machine
2. High mandrel pressure Storage , loading
Crease Issue & center
13 VK Metal BLR issue unlading practice
Packing Issue [Link] use of boom stac
3. Poor packing materail 2. reevaluate the
ker, hook crane, or battery floo
and SOP is not defined at Packing process for any
r crane
plant improvement
4. Share safe handling guidelines VK Metal, Agra

4. Customer may have no Godown Visit Report

Date: 20-05-25

in eyetowall storage format

right SOP to unloading and Attendance:

Hindalco:
Hemant (Tech Rep)
Kundan (Quality, BLR)
VK Metal :
Amit
Pradeep

storage 1
Customer Complaint highlights:
Case
S.N Customer Plant Possible Cause Improvement Effect
Description Pic/Doc
[Link] in SOP for
1. Understaing
branding. [Link] /OPL for shop floor
scope of
2. No system to team
improvement in
Branding detect/Alarm the 2. Guide for exlporing
13 Metal Trader BLR Branding missing
Missing bradming missing Kaizen project for
case
3. semiskilled manpower improvement
2. Adherance for
4. Manual inspection
repetative case
missing

new part ID (POKA

AA8011 H16
Parity Material failed for fan New part ID created for Yoke) to prevent
14 (UTS 170– BLR
Consumer blade fan blade parity future case for
180)
same application

1. Verified trimming issue;

Edge Ripple 1. Stop potentail
scrapped stock (10.5 T)
– AA1200- 1. Trimming issue fright charge loss &
15 Metalco TLJ [Link] to OPL and
H14-0-920- 2. Heavy input bow upcoming
Preventive actions shared
2.5 complaint
to avoid future complaints
Process Improvement Case/trails;

S.N Customer Case Description Plant Possible Cause Improvement Effect Pic/Doc

1. levelling issue due [Link] trust

to bow in input coil [Link]/slitting building
Process 2 wrong leveler calibration done 2. will help for future
1 Akash Development setting 2. Share feeback and requirement for
Support 3. wrong leveler possible defects due slitting/Leveling in
calibration Leveler/Slitting case plant is not
feasible to do.

1. Low quality packing Revised packing

mutual trust building
Poor Packing material material (rubberized
2 Tarachand Fojmal TLJ for improvement
Quality 2. Non-standard sheet from Next Photo [Link]
No new complaint
material used onwards positively) packing materail improve_ SR-0000128202_ [Link]

Wrong TC & data

shared: AA1200 H14 Found incorrect
Misleading Case mutual trust building
3 VK Metal not supplied as material/TC shared
(VKMetal) with VK Metal
promised (sample by Tapodani
tested-AA3003 RE_ Spec AA1200 H14, Appreciation for Your Effort on RCA_Analysis.eml
Process Improvement Case/trails;

Case
S.N Customer Plant Possible Cause Improvement Effect
Description Pic/Doc
1. %Elong, min – as per
EN 485-2 is 2-3 % 1. Process mapping and other
Higher 2. No past case study details Share with HIC to Under Development
Metal Paint,
4 Elongation >5% RKT of higher Elongation for analysis (few samples of 0.4 mm
export
in AA3105 H27 AA3105 2. under discussion with RKT, trail from at HIC)
[Link] 6 months for HIC & marketing
trails (RKT)

1. Input coil thickness

1. HIC looped in to identify
variation 1. Understaing the
cause, closing working with
BMR Roll Bend 2. Process change at possibility of crack issue
5 BLR, FRD BLR HIC
Cracking Issue customer end from plant side or after
2. Shared report for process
3. Edge of sheet delivery
mapping
damaging roll 2. Mutual trust building
[Link] CC coil needs
1. Wrong material
homogenization for same 1. Learning from failure
2. Missing mechanical
BMR CC Route application, only 20% sample 2. sample anyasis for
6 BMR External properties
Trials success; both Jindal and
3. Customer processing
2. 2nd trail hold for plant Metenere preserved
error
supply issue
Opportunities to Improve
S.N Customer Case Description Plant Possible Cause Improvement Effect Pic/Doc
1. Internal NC rejection
1. coil were found touching
1. Share feedbacks & at Customer end
coil storage eachother, may lead case of
7 Chengfeng TLJ customer implimented 2. Guiding Customer for
improve handling damaged (internal
the change better & safe working
NC)
place
1. Training : 5S &
1. Guiding manpower
1. multiple defects observed adopataion culture to
5S and basic for better & safe
due to slitting & unhygenic improve
8 NA defects anaysis Metenere working place
issue 2. Basic defects
training 2. furture rejection
2. semiskilled manpower caterization, RCA, control
reduce.
plan

1. Multiple times visiting

Customer for validation 1. Understaing the
1. Recoiler mandrel slots
of RCA possibility of defect
impression
2. Guide for hygenic from plant side or after
2. 3rd party toller mandre
coil cutting sheet cutting and delivery
9 Angles Al HKD/RKT slots impression
issue/arbor break possible cause of issue 2. multiple sites
3. high mandrel pressure
3. As it is mix defects , capabiltiy check for
4. no use of belt wrapper
asked plant team to better production
validate and control 3. still working on
possible solution