83. A Case Study – Positive Grid Corrosion

83. A Case Study – Positive Grid Corrosion

In this episode of my podcast, I share a real-life case study from a recent visit to the automotive battery industry. A manufacturer was experiencing many warranty claims due to positive grid corrosion. To solve it, they strengthened the grid by adding extra horizontal and vertical wires. The corrosion issue improved—but a new set of problems emerged. * Battery capacity reduced * OEM customers were unhappy with the heavier battery * Assembly processes had to be modified * Recharge time became longer One solution had triggered a chain of unintended consequences. When we stepped back and investigated the problem scientifically, we discovered that the real issue wasn't the grid design at all. The original corrosion problem was resolved—without redesigning the battery. This experience reinforced a lesson that applies far beyond batteries: Never treat the symptom before understanding the cause. In engineering, and in life, solving one visible problem without identifying its root cause often creates several new ones. A systematic, holistic approach almost always leads to a simpler, more effective, and more economical solution. I hope this episode provides useful insights for professionals in battery manufacturing, quality, R&D, and process engineering. I'd love to hear your thoughts: Have you ever seen a "solution" create more problems than the original issue? SHARE YOUR FEEDBACK [https://www.buzzsprout.com/1963960/fan_mail/new] * Visit, www.RameshNatarajan.in [https://www.RameshNatarajan.in] to stay connected * Join my network on LinkedIn [https://www.linkedin.com/in/ramesh-natarajan-4ab864139/] to engage on social media * View my videos on my Youtube Channel [https://www.youtube.com/@rameshnatarajankailad8790/videos] to get further insights of Lead Acid Batteries

82. The Write Inheritance: How Words Build Legacies

In this inspiring episode of The Write Inheritance, industrial marketer Bejoy Peter sits down with Ramesh Natarajan, well-known author and battery industry expert to explore the powerful connection between writing, influence, and legacy. From factory floors to life as a best-selling author, Ramesh shares how his journey through the world of batteries sparked stories that charge minds and move hearts. Together, Bejoy and Ramesh unpack the creative process, the discipline of writing amidst demanding careers, and why every professional - no matter their field - has a story worth telling. Expect witty insights, honest reflections, and a few “aha” moments that will make you rethink what your words can leave behind. Because in the end, ideas fade but what you write, lives on. SHARE YOUR FEEDBACK [https://www.buzzsprout.com/1963960/fan_mail/new] * Visit, www.RameshNatarajan.in [https://www.RameshNatarajan.in] to stay connected * Join my network on LinkedIn [https://www.linkedin.com/in/ramesh-natarajan-4ab864139/] to engage on social media * View my videos on my Youtube Channel [https://www.youtube.com/@rameshnatarajankailad8790/videos] to get further insights of Lead Acid Batteries

81. Stop Losing Power: The Connection Mistake Most Forklift Users Make

“Bolt it, or burn it?” That’s the question I explored in my latest podcast episode. Both bolt-on and weld-on cell traction batteries have their pros and cons — but the real difference shows up in: * How they’re serviced, * How they’re maintained, and * How long they last. Most people think bolt-on cells are “better and convenient,” but do they realize the equalization step can make or break the battery’s life? Listen in as I explain why ease of service doesn’t always mean better performance. SHARE YOUR FEEDBACK [https://www.buzzsprout.com/1963960/fan_mail/new] * Visit, www.RameshNatarajan.in [https://www.RameshNatarajan.in] to stay connected * Join my network on LinkedIn [https://www.linkedin.com/in/ramesh-natarajan-4ab864139/] to engage on social media * View my videos on my Youtube Channel [https://www.youtube.com/@rameshnatarajankailad8790/videos] to get further insights of Lead Acid Batteries

80. 11 Guidelines for Success in the Battery Industry

🔋 What does it *really* take to succeed in battery manufacturing? It’s not just about chemistry and machinery. In my latest podcast episode, I discuss 11 powerful (and often overlooked) guidelines that separate thriving battery businesses from the ones that quietly disappear. This isn’t your typical technical talk — it’s about the real challenges, the silent killers of profitability, and the strategic decisions that matter most. Whether you're a manufacturer, entrepreneur, or industry enthusiast, this episode will give you insights you won't find in textbooks. I'd love to hear your thoughts after listening.  ⚡ Let’s spark a conversation.  #BatteryIndustry #ManufacturingLeadership #Podcast #BusinessStrategy #BatteryManufacturing #IndustrialInsights #Entrepreneurship  SHARE YOUR FEEDBACK [https://www.buzzsprout.com/1963960/fan_mail/new] * Visit, www.RameshNatarajan.in [https://www.RameshNatarajan.in] to stay connected * Join my network on LinkedIn [https://www.linkedin.com/in/ramesh-natarajan-4ab864139/] to engage on social media * View my videos on my Youtube Channel [https://www.youtube.com/@rameshnatarajankailad8790/videos] to get further insights of Lead Acid Batteries

79. Bubbles on pasted plates – Why? A case study.

Bubbles on Pasted Plates… but why? Everything looked normal. •Same paste formula. •Same raw materials. •Same paste chemical additives •Same machine settings. But over 50% of the plates were getting rejected. Right after pasting. Before even reaching the drying oven.  The QC team tried everything—tweaking the mix, rechecking materials, and recalibrating equipment. Still, the problem persisted.  👉 Then came a phone call. And a video. 🔍 What followed was a surprising discovery 🎧 In this case study, I walk you through a puzzling situation from a battery factory floor where logic, observation, and fresh eyes led to a surprising yet straightforward fix. To hear an engaging narrative, please tune in to this episode of my podcast. SHARE YOUR FEEDBACK [https://www.buzzsprout.com/1963960/fan_mail/new] * Visit, www.RameshNatarajan.in [https://www.RameshNatarajan.in] to stay connected * Join my network on LinkedIn [https://www.linkedin.com/in/ramesh-natarajan-4ab864139/] to engage on social media * View my videos on my Youtube Channel [https://www.youtube.com/@rameshnatarajankailad8790/videos] to get further insights of Lead Acid Batteries