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?

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