Customer
Energy Sector – Power & Manufacturing
Product
Tilting trolley
Industry
Power & Energy — Manufacturing
Project Overview
The customer relied on a capacitor tilting trolley that was previously imported from Europe. As production demand increased, the team required additional units but faced challenges such as long lead times, high import costs, and slow supply responsiveness.
Venttup partnered with the customer to localise the trolley, reduce dependency on imports, and streamline the production workflow.
Objectives
- Develop a locally manufactured version of the capacitor tilt trolley
- Reduce lead time and procurement costs
- Maintain the same quality and functionality as the imported equipment
- Deliver a fully tested, production-ready system
Challenges
- No existing local version of the equipment
- High waiting time due to European supply chain
- Need for precise engineering replication (reverse engineering)
- Ensuring smooth integration into the customer’s operational environment
Venttup’s Approach / Process
1. Initial Assessment
Venttup analyzed the imported trolley and captured the entire mechanism through a hand sketch and on-site study.
2. Product Observation & Technical Drawing
The engineering team conducted detailed observation and created accurate technical drawings needed for local manufacturing.
3. GATE Process Initiation
A structured GATE (stage-gate) process was implemented to ensure:
- Alignment with Hitachi’s requirements
- Transparent design validation
- Risk-free product development stages
4. Reverse Engineering & Local Development
- Venttup reverse-engineered the original equipment
- Design was reviewed and approved by the customer
- A prototype was developed in Coimbatore
- The prototype underwent rigorous testing and quality checks
5. Deployment & Operation
The final product was delivered and is now successfully operating at the customer’s facility, performing at par with the imported version.
Outcome & Impact
30% Reduction in Lead Time
Local production eliminated long import waiting periods.
25% Cost Savings
Manufacturing the trolley locally reduced overall procurement costs.
Improved Operational Efficiency
Reliable supply, faster fulfilment, and easier maintenance resulted in higher productivity for the customer’s team.
Key Highlights
- Complete localisation of an imported industrial trolley
- Faster turnaround time for production expansion
- Cost-efficient engineering without compromising quality
- Smooth adoption into daily operations at Hitachi
Conclusion
Venttup’s localisation support helped the customer in the energy sector overcome import-related challenges and achieve significant improvements in cost, efficiency, and delivery speed.
This project highlights Venttup’s expertise in reverse engineering, product localisation, and customised industrial solutions for large-scale manufacturing environments.
