From customer requirement to mass production
A dedicated department developing and improving manufacturing processes — robust, repeatable and scalable, established before mass production begins.
Ten areas of process development
Press Tool Development
From laser / turret punching to dedicated press tools and part-specific tooling.
Faster & economicalPress Capacity Expansion
20 → 150 Ton — small, medium, large & heavy components across material thicknesses.
Wider capabilityProgressive Tooling
Multiple sequential operations integrated into one consistent, high-output process.
Shorter lead timeBending Development
Press brake → power press tooling & roll forming, with a panel bender planned next.
Consistent bendingWelding & Fabrication
CO₂ welding → laser & fixture-based welding, moving toward robotic welding.
Better consistencySurface Treatment
Zinc phosphating & powder coating, expanded with CED for application-specific protection.
Longer product lifeAssembly Development
Manual assembly → torque-controlled guns, special fixtures, auto-feed & clean room.
Reliable assemblyPackaging Development
Standardized, product-specific protection against scratches, impact, dust & transit damage.
Reduced transit damageRapid Prototyping & NPD
Design → DFM → prototype validation → improvement → production, compressed.
Faster launchProcess Standardization
Standard work methods, parameters, tooling, fixtures, inspection & work instructions.
Repeatable processGlimpse of the facilities
Tool Room
A dedicated tool room that builds and maintains our press tools, progressive tools and fixtures in-house — keeping development fast and tooling always production-ready.
From conventional manufacturing to engineered solutions
| Area | Engineering improvement | Customer value |
|---|---|---|
| Cutting | Laser / Turret → Press Tooling | Faster & economical |
| Forming | Press Brake → Press Tools / Roll Forming | Higher productivity |
| Welding | CO₂ Welding → Laser & Fixture Welding | Better consistency |
| Surface | Phosphating + Powder → CED + Powder | Better protection |
| Assembly | Manual → Torque / Fixtures / Auto Feed | Reliable assembly |
| NPD | Conventional → Rapid Prototyping | Faster development |
| Packaging | No standard → Standardized Packaging | Better protection |
A framework that gets it right the first time
The Engineering Excellence team runs every new product through a ten-step workflow, held to eight quality gates — with dedicated manufacturing assets behind it.
Rapid Product Development
First Time Right
Knowledge Sharing & Horizontal Deployment
End-to-end NPD workflow
- Drawing Receipt
- BOM & Job Card Preparation
- DFM & Process Planning
- Costing & Material Requisition
- Material Availability Check
- Drawing Review & Correction
- Tooling / Fixture Development
- Programming & Sample Manufacturing
- Stage-wise Inspection & PPAP
- Final Inspection & Customer Approval
8 quality gates
- Drawing verification
- DFM review
- Tooling readiness approval
- Sample stage inspections
- Inspection reports
- PPAP documentation
- Final inspection approval
- Customer submission
Manufacturing assets
One window for all cabinet samples of Vertiv
Outcomes
- Faster new product introduction
- Reduced engineering errors
- Improved manufacturability
- Robust quality assurance process
- Part traceability through QR systems
Running today. Building next.
Running on the floor now
- Press & Progressive Tooling
- Roll Forming
- Laser & Fixture-Based Welding
- CED
- Torque-Controlled Assembly
- Rapid Prototyping
The engineering roadmap
- Panel Bender
- Robotic Welding
- Further Process Automation
- Advanced Inspection & Digitalization
- Increased Process Integration
Bring us your next product.
Our NPD team takes it from drawing to approved sample — first time right.