Batteries Demystified by Ramesh Natarajan

In every process-oriented industry, we invest heavily in technology, automation, and quality systems.

Yet one of the biggest causes of quality issues often has nothing to do with machines or materials.

It is the gradual drift away from “Standard Operating Procedures” (SOPs)—often by the most experienced employees who believe they know a “better” or “faster” way.

Have you experienced situations where overconfidence or informal shortcuts compromised quality? How does your organization ensure that SOPs are consistently followed while still encouraging continuous improvement?

Having spent over 42 years in the lead-acid battery industry, I have witnessed how seemingly insignificant deviations from SOPs can eventually lead to inconsistent quality, increased warranty claims, higher manufacturing costs, and dissatisfied customers.

Experience is invaluable, but it should strengthen SOP compliance—not replace it.

In my latest podcast, I share why SOPs are much more than documents—they are the collective wisdom of an organization, built on years of experience, trials, failures, and continuous improvement.

I also discuss practical ways organizations can strengthen SOP compliance without discouraging innovation.

I would love to hear your thoughts on this topic.

#Leadership #Quality #Manufacturing #Operations #StandardOperatingProcedures #SOP #ContinuousImprovement #OperationalExcellence #QualityManagement #LeanManufacturing #IndustrialEngineering #BatteryIndustry

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How do we balance environmental responsibility with industrial competitiveness?

Because true sustainability is achieved not by making business difficult, but by creating regulations that reward compliance, encourage investment, and ensure a level playing field for every stakeholder.

The lead-acid battery industry has already demonstrated that a mature circular economy is possible. The lithium-ion industry is now building its own recycling ecosystem. Policymakers have a unique opportunity to learn from the strengths of both technologies and create regulations that accelerate sustainability without compromising industrial growth.

After all, the future of energy storage will not belong to a single battery chemistry. Different applications require different technologies, and each plays an important role in India's journey toward a cleaner and more sustainable future. 

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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?

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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.

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“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.

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🔋 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 

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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.

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Battery manufacturers specify the end-of-discharge voltage based on battery design and application.

Any discharge below the end of the discharge voltage is termed a deep discharge. Deep discharges, especially when more frequent, lead to battery capacity loss and degradation of the active material. Batteries subjected to deep discharges fail prematurely.

In the case of lead-acid batteries, deep discharges damage both the positive and negative electrodes.  

Sporadic and infrequent low voltages for a short period caused by a high current drawn from the load cannot be considered deep discharge.

To understand the phenomenon of deep discharge, please tune in to this episode of my podcast, available on various streaming platforms.

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Electric vehicles, or EVs as they are more popularly known, are a sunrise sector with a lot of government encouragement so that car buyers shift to EVs from Internal Combustion Engine vehicles. Internal Combustion Engine vehicles are referred to as ICE vehicles.

EV buyers are lured by the fuel cost savings that will accrue to them when they buy an EV.

However, any fuel cost savings accrued to an EV owner have to cover the 

• higher cost of EVs compared to ICE vehicles, 
• insurance premium riders, 
• high and probable maintenance expenses, 
• battery replacement cost, 
• roadside assistance charges, and 
• the extra cost of towing the car. 

Regarding Total Cost of Ownership, the savings accrued after these expenses are covered can be considered real savings.

Operational savings accrued every month are, at best, an eyewash. 

This podcast episode also dwells upon other issues, such as battery recycling and vehicle resale costs.

Another unmissable episode for all EV users, dealers, and battery manufacturers.

To hear this enlightening episode, please tune in to this episode of my podcast.

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Did you know that Lithium-Ion batteries are not similar to lead-acid batteries in terms of safety and handling procedures?

The popularity of lithium-ion batteries has resulted in the spawning of many dealers, traders, and assemblers of cells and modules. This is a good development, but many entrepreneurs are unaware of the risks associated with lithium-ion batteries. 

Hence, I considered doing this podcast episode focusing on the facilities to be incorporated in the battery rooms, keeping safety in mind.

I have touched upon the main aspects to consider when designing a battery room, and I hope this list is as comprehensive as possible. 

Lead acid battery manufacturers and dealers must listen to this episode.

To hear this informative episode, please tune in to this episode of my podcast.

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