Aggregate Idea Description Savings (INR) DMN Release Target

ABS Trims (Thickness) Part thickness optimization from 2.5 mm to 2/1.5 mm or 4

4796 Apr'23
22 parts mm to 3 mm

ABS Trims (Thickness) Part thickness optimization from 2.5 mm to 2/1.5 mm or 4

1412 Apr'23
4 parts mm to 3 mm

Driver Seat Design modification of seats 1500 May'23

Last Row Seats Design modification of seats 4500 May'23

Dashboard Design optimization of Dashboard assy. (design similar to T2,

15000 May'23
(VF -> FRP) thickness reduction) -> ABS vacuum forming to FRP

Window Window to be designed in single frame similar to Eicher 10000 June'23

Leaf Spring - Parabolic Leaf reduction from 5 to 4 considering same performance 3000 June'23

Yield optimization, machining elimination of child parts of

Exhaust System 1599 June'23 Onwards
exhaust

Air Cleaner Plastic air cleaner instead of current air cleaner 1600 June'23 Onwards

Total 43407
Supplier Name Supplier Meeting Supplier Visit Next Steps

Pinnacle Done Done Fitment found okay. R&D to raise DCR

Pinnacle Done Done ADD to arrange part with higher thickness

Pinnacle Done Done Samples received. PAVE test to be completed by 5th May'23

Pinnacle Done Done Samples received. PAVE test to be completed by 5th May'23

Final 3D section shared by supplier. R&D to revert with design

Techforce Done Done
clarification on open points of aesthetics, features, etc.

Sample to be available by 15th Apr. Supplier visit planned on

Mahavir Done Done
10th Apr'23

Agya Auto Under Planning Under Planning Drawings approved. Sample to be received by 15th Apr'23

Joint meeting to be arranged with supplier to discuss and

Sharda Motors Under Planning Under Planning
validate ideas

R&D has shared the final confirmation to supplier on

Fleet Guard Done Under Planning
packaging signoff. DFM data awaited from supplier
 Responsibility
(ADD & R&D)

Anand Jawale
Sujit Banginwar

Anand Jawale
Sujit Banginwar

Anand Jawale
Sujit Banginwar

Anand Jawale
Sujit Banginwar

Anand Jawale
Sujit Banginwar

Anand Jawale
Sujit Banginwar

Vasant Khandade
Sachin Mane

Anant Patil
Ganesh Patil

Sandeep Kshatriya
Chandrakant Khacahne
 Aggregate Idea Description

Wheel Hub Cover Conversion from ABS Vacuum forming to FRP

Emergency Switch Emergency switch optimization (reduced 2 no's)

Dealer fitment provision of window rail assembly inline with that of

Window Rail
Eicher

Elimination of Horizontal Hand Hold Pipe and Horizontal stanchion

Horizontal Bar
bar mtg. rail

Stretch Panel C channel to be converted to L Channel

Footrest Plate Assy (Child Footstep) Tube thickness to be reduced to 1.5 mm from 2mm

Inner Side Wall Panel Modifying the current inner side wall panel material from Aluminium to
Al -> GI Sheet Paint coated GI sheet

Battery Box Conversion of part from FRP to Sheet Metal

FRP extruded pipe with diameter of 18 mm in place existing from 19

Window Rail (FRP Extrusion)
mm sheet metal part

Sticker/Tapes School bus sticker on front windshield and rear window to be deleted

Replacing the 6+6 kg fire extinguisher system with 6+4 kg fire

Fire Extinguisher
extinguisher system

Design optimization of urea tank structure , Optimization of tube,

Urea Tank Frame
bracket thickness

Design optimization of stepwell guard, ERW Tube and 3-way

Driver Partition
connectors

Front Tow Hook Tow hook to be fabricated and designed similar to SML

Battery Frame Square tube thickness to be changed to 1.5 mm from 2mm

Gear Shifter ERW SQ tube Thickness to be changed to 1.2mm (25*25*2)

Pedals & Bevel Gear Mtg Bkt Pedal thickness reduction from 7mm to 6mm/5mm inline with Eicher b

Sealant- Sliding Window Sealant optimization on Sliding Windows

Service cap cover & floor cover Part to be converted to FRP from ABS Vacuum forming

1 large hammer to be deleted, 2nd large hammer size reduction, 2

Hammer
small hammer to be changed with Urbania type hammer

Deletion of luggage compartment lamp as there is no dickey in school

Dickey Lamp
bus
Door Structure Rectangular tube to C tube; Thickness to be changed to 1.5 mm

Driver Fan Driver fan from LAPL to be explored

Seat Cover Part to be converted to sheet metal from ABS vacuum forming part

Chequered Plate Thickness to be changed to 1.5 mm from 2mm

BIW High (Thickness) Thickness reduction from 1 mm to 0.8 mm

HSLA -> D 513 Material to be changed to D 513 from HSLA ( 1mm)

Pulleys To change to sheet metal from existing casting and machining

Modifying the current floor material from Bubble sheet (12mm) to

Bubble Floor
Plywood (8mm)

Mudflap Design modification

Total
 15-Apr-23

Savings DMN DMN Release Days Since

Current Situation & Next Steps
(INR) Number Date DMN Release
Proposal to be submitted to PP, Tooling go-ahead to be
1200 17750 15-Mar-23 31
given

Quotation of wiring harness to be shared,

410 17616 9-Mar-23 37
implementation planned in Apr'23

Existing stock of 17 nos. Implementation plan to be

2668 17522 8-Dec-22 128
shared

Implementation will be done post manufacturing of 68

2067 17523 8-Dec-22 128
vehicles

316 17709 8-Mar-23 38 Materials team to share implementation plan

Modified samples arranged. Implementation to be done

169 17695 1-Mar-23 45
post manufacturing of 45 Vehicles.. Price settled

Proposal submitted to PP on 21st Mar, settlement to be

5000 17582 13-Jan-23 92
done

Sample to be arranged by 11th Apr'23, negotiation

480 17639 17-Feb-23 57
under progress

70 17755 27-Mar-23 19 Implementation plan to be shared

122 17554 9-Jan-23 0 Implemented

75 17586 1-Feb-23 73 Implementation planned in Apr'23

Price settled. ADD to re-submit PRR for price

482 17612 17-Feb-23 57
amendment

ADD to share supplier feedback. Trials to be

400 17701 1-Mar-23 45
conducted. Re-DMN in progress

178 17636 17-Feb-23 57 Price settled, sample to be arranged by 15th April

Price settled. Sample to arrive by 7th Apr. Existing

145 17564 17-Feb-23 57
stock of 180 nos.
Received 20 nos. from supplier. Implementation will be
115 17585 1-Feb-23 73
done post manufacturing of 140 vehicles
Bevel Mtg. Bkt - Feedback awaited from supplier for
85 17605 & 17629 17-Feb-23 57 tooling, samples to be arranged
Pedals: Quotation received, PRR to be done
1181 17570 13-Jan-23 92 Implemented

Samples arranged. Trials to be planned.

881 16149 12-Jan-23 93
Implementation plan to be shared

Implementation to be done post manufacturing of 150

320 17631 17-Feb-23 57
vehicles

Implementation to be done post manufacturing of 735

282 17652 17-Feb-23 57
vehicles
 Modified samples arranged. PO to be released. Doors
235 17466 3-Nov-22 163
inspected & found okay.

85 17624 17-Feb-23 57 Implementation planned in Apr'23

80 17694 1-Mar-23 45 Implementation planned in May'23

10 nos. received on 14th Mar'23. Price settled. Existing
20 17528 26-Dec-22 110
stock of 45 nos.
PE team to share trials status & implementation plan to
691 17692 15-Mar-23 31
be shared
17525 & PE team revised process sheet, implementation plan to
109 17-Feb-23 57
17587 be shared
Adapter received. 20K km vehicle level validation to be
621 17710 1-Mar-23 45
done

Commercials received on 1st Mar'23. Part code to be

8698 17580 13-Jan-23 92
shared by R&D. Re-DMN to be released by 10th Apr

Assembly drawing to be shared, 3 proposals to be

1000 17708 8-Mar-23 38 submitted to PP for negotiation. Re-DMN in progress
by 22nd Apr'23

28185
 Department Responsibility Adherence Sample Plan

ADD + PP + RM Purchase Anand Jawale In-progress 15-Apr-23

ADD + PP + RM Purchase Hemant Dewani In-progress

ADD + PP + RM Purchase Mandeep Walia In-progress 15-Apr-23

ADD + PP + RM Purchase Mandeep Walia In-progress 15-May-23

ADD + PP + RM Purchase Mandeep Walia In-progress 30-Dec-99

Mandeep Walia
ADD + PP + RM Purchase In-progress Done
Mukund Paramane

ADD + PP + RM Purchase Mukund Paramane In-progress

ADD + PP + RM Purchase Mukund Paramane In-progress 15-May-23

ADD + PP + RM Purchase Nikhil Boonlia In-progress 15-May-23

ADD + PP + RM Purchase Sandeeep Kshatriya Completed 30-Dec-99

ADD + PP + RM Purchase Sandeeep Kshatriya In-progress 30-Dec-99

ADD + PP + RM Purchase Siddu Hullur In-progress 30-Dec-99

ADD + PP + RM Purchase Siddu Hullur In-progress 27-Mar-23

ADD + PP + RM Purchase Siddu Hullur In-progress 30-Dec-99

ADD + PP + RM Purchase Siddu Hullur In-progress Done

ADD + PP + RM Purchase Siddu Hullur In-progress 15-Apr-23

Siddu Hullur
ADD + PP + RM Purchase In-progress Mar'23 30-Dec-99
Mandeep Walia

PE + Production Amitabh Gupta Completed 1-May-23

PE + Production Amitabh Gupta In-progress 30-May-23

PE + Production Amitabh Gupta In-progress 30-Mar-23

PE + Production Amitabh Gupta In-progress 25-Apr-23

PE + Production Amitabh Gupta In-progress Received

PE + Production Amitabh Gupta In-progress 20-Mar-23

Clutch Pedal- 4/20/2023

PE + Production Amitabh Gupta In-progress
Brake pedal - 10 May
PE + Production Amitabh Gupta In-progress 5-Apr-23

Arun Joshi
PE + Production In-progress 30-Dec-99
Mandar Ghaisas

PE + Production Mandar Ghaisas In-progress 30-Dec-99

R&D (Engineering) Sajan Abraham In-progress 30-Dec-99

Suresh Pacharne
R&D (Engineering) In-progress 30-Dec-99
Sujit Banginwar

Suresh Pacharne
R&D (Engineering) In-progress 30-Dec-99
Sujit Banginwar
Implementaio
n Plan

15-Apr-23

15-Apr-23

15-May-23

30-Dec-99

Done

15-May-23

15-May-23

30-Dec-99

15-May-23

15-Apr-23

15-Apr-23

15-May-23

Done

15-Apr-23

15-Mar-23

15-May-23

15-Jun-23

5-Apr-23

25-Apr-23
1-May-23

1-May-23

1-Jun-23

15-Apr-23

30-Dec-99

1-Jun-23

15-May-23

30-Dec-99

Done
 Aggregate Idea Description

ABS Trims (Thickness)

Part thickness optimization from 2.5 mm to 2/1.5 mm or 4 mm to 3 mm
8 parts

ABS Trims (Thickness)

Part thickness optimization from 2.5 mm to 2/1.5 mm or 4 mm to 3 mm
4 parts

Anti Vibration Knob Alternate sourcing / negotiation of Knob from Darshana industries/ other suppliers

New Lamp (Without Driver

New inner LED light to be used (similar to Tata)
Circuit)

Class 6 Mirror ORVM mounting to be optimized (similar to Eicher), and Cap to be eliminated

Choke Block Wooden/ plastic chock block is to be used in place of sheet metal similar to Eicher

ABS Trims (Thickness)

Part thickness optimization from 2.5 mm to 2/1.5 mm or 4 mm to 3 mm
22 parts

ABS Trim (Electrical Comp

Design optimization of ABS part (Thickness reduction across cover & flap)
Assy.)

ABS Rear Dome Single piece/optimized design with reduced thickness

Edge Finisher (ABS) New design development (ABS -> PP Extrusion)

Button type anti skid vinyl sheet to be used in place of silicon embedded vinyl or
Vinyl Sheet
thickness to be changed to 1 mm

Footstep (Passenger & Driver) Optimization of Passenger footstep - Design Optimization & FRP to sheet metal

Total
Savings DMN Release
Current Status
(INR) Target

1661 Apr'23 sample with reduced thickness is inspected

1412 Apr'23 sample with reduced thickness is inspected

500 Apr'23 Samples arranged. Testing done & found okay

1300 Apr'23 Samples arranged by ADD for testing

Fitment completed, subjective assessment done

200 Apr'23
& found okay

410 Apr'23 R&D has shared input requirement

4796 Apr'23 sample with reduced thickness is inspected

5385 22-Apr-23 Supplier has shared techno-commercial offer

Commercial quotation shared by supplier on

4539 22-Apr-23
revised design

1917 22-Apr-23 Test completed & found okay

1500 22-Apr-23 Test completed and found okay

700 22-Apr-23 Drawings to be completed, DMN to be released

24320
 Next Steps Department Responsibility Adherence

ADD to arrange parts with higher thickness for ADD + PP + RM

Anand Jawale In-progress
inspection Purchase

ADD to arrange parts with higher thickness for ADD + PP + RM

Anand Jawale In-progress
inspection Purchase

ADD to share supplier drawing for DCR and DMN ADD + PP + RM

Anand Jawale In-progress
release Purchase

Testing at ARAI completed. Report to be shared. ADD + PP + RM

Sandeep Kshatriya Delay
Drawings to be submitted by supplier Purchase

ADD + PP + RM
ADD to share component level certificate Sandeep Kshatriya In-progress
Purchase

R&D testing team to share test report & DCR to be

R&D (Engineering) Ashish Ingale In-progress
raised by R&D Engineering team

Fitment found okay. R&D to raise DCR by 11th Apr'23 R&D (Engineering) Sujit Banginwar In-progress

Suresh Pacharne
Adherence to DMN release target R&D (Engineering) In-progress
Sujit Banginwar

Suresh Pacharne
DCR raised. DMN to be released R&D (Engineering) In-progress
Sujit Banginwar

Suresh Pacharne
DCR raised, DMN to be released R&D (Engineering) In-progress
Sujit Banginwar

Suresh Pacharne
DCR raised. DMN to be released R&D (Engineering) In-progress
Sujit Banginwar

Suresh Pacharne
Adherence to DMN release target R&D (Engineering) In-progress
Sujit Banginwar
7 (window - 8600 ml sauces - 409 Rs

5521.5
 Savings
Aggregate Idea Description
(INR)
Month

Last Row Seats Design modification of seats 4500

Tire Usage of 225 /75R 17.5 size (33+D) for 41+D school buses (235 R) 3500

Passenger Seats Design modification of seats 3000

Driver Seat Design modification of seats 1500

Luggage Compartment Lamp Elimination of secondary harness connection for luggage compartment
200
Harness lamp

Dashboard Design optimization of Dashboard assy. (design similar to T2, thickness

15000
(VF -> FRP) reduction) -> ABS vacuum forming to FRP

Total 27700
DMN Release
Current Status Next Steps
Target

R&D has raised test request. Samples

May'23 PAVE test to start & completed by 5th May'23
received

25000 endurance cycle to be completed & R&D to

May'23 Around 23800 km endurance test completed extrapolate tire life & take decision. Speed limiting device
test to be planned, ESP test - ZF confirmation required

R&D has raised test request. Samples

May'23 PAVE test to start & completed by 5th May'23
received
May'23 Sample received PAVE test to start & completed by 5th May'23

May'23 Supplier confirmation savings received R&D to release the DCR

Final 3D section shared by supplier. R&D to revert with

M/s ACE Engineering & Techforce has
May'23 design clarification on open points of aesthetics, features,
shared technical proposal
etc.
 Department Responsibility Adherence

R&D (Engineering) Balwant Shedbal In-progress

R&D (Engineering) Balwant Shedbal Delay

R&D (Engineering) Balwant Shedbal Delay

R&D (Engineering) Balwant Shedbal In-progress

R&D (Engineering) Prasant Shitole In-progress

R&D (Engineering) Sujit Banginwar In-progress

 Savings
Aggregate Idea Description
(INR)

Window Window to be designed in single frame similar to Eicher 10000

BIW High (Thickness) Thickness change of BIW parts 1575

Total 11575
DMN Release
Current Status Support Required
Target
M/s Mahavir has shared the technical & Sample to be available by 15th Apr. Supplier visit planned on
June'23
commercial proposal 10th Apr'23

Trail plan shared for 7 parts, Plan to be shared

June'23 Results of CAE analysis awaited from ARAI
for all th parts post PE approval
 Department Responsibility Adherence

ADD + PP + RM Purchase Anand Jawale In-progress 690 dg 33+D , 4 to 5 41+d -8

Venkataramana
R&D (Engineering) In-progress
Anumula
DMN Release Target

Months Dec'22 - Apr'23 May'23 June'23 June'23

Mar'23 beyond
Plan Values (INR) 28185 24320 27700 11575 11699
T3 Actual Values
Values (INR) 28185
Plan Values (INR) 19243 9328 9826 - 10314
Trax Actual Values
Values (INR) 19243
Total Plan Values (INR) 47428 33648 37526 11575 22013