Battery cell manufacturing

Battery Cell Production Smart Factory

Initial Situation and Objective: A standardized intralogistics blueprint was developedfor battery cell production that serves as a reference concept (white paper) and can be applied and scaled across various production sites.

Customer Requirements: Cross-site standardization of logistics processes, including ISO 9001-compliant documentation and migration to SAP Signavio.

Solution / Implementation: Planning and evaluation of logistics equipment, as well as modeling, layout, and standardization of internal logistics, including container concepts.

Your benefits: Aglobally deployable standard logistics concept and factory blueprint as a reference for standardized factory implementations.

Ramp-up Management (Task Force & SAT)

Customer Need: Ensure delivery capability and optimize the plant ramp-up in a targeted manner.

Solution / Implementation: Task force for each plant area (conveyor technology, cell assembly, formation & aging), process and quality measures (reduce scrap), as well as supplier tracking including escalation management and KPI reporting.

Your Benefits: Higher plant availability and output, assured quality targets, and a coordinated material flow.

Pretreatment & Intralogistics Optimization

Customer requirements:
Optimization of material flow in pretreatment and integration of high-performance conveyor technology for efficient supply to production processes.

Solution / Implementation:
Introduction of decoupling buffers to stabilize material flow, optimization of conveyor systems, and reduction of internal transport and process inefficiencies.

Your Benefits:

• Reduced operating costs due to lower energy and equipment requirements
• More efficient production processes through stabilized material flows
• Reduction in the number of actuators while maintaining performance

Pre-Basic Engineering & Factory Planning

Initial Situation and Objective:
A solid foundation for time and cost assessment during the setup of battery cell production.

Customer needs:
Early validation of investment and production scenarios.

Solution / Implementation:
Scalable factory concept including layout and infrastructure planning as well as variant evaluation.

Your benefits:

• High planning reliability (CAPEX, OPEX, footprint)
• Clear basis for decision-making
• Fewer interfaces thanks to integrated planning

Containment & Plant Safety

Customer needs:
Safe handling and containment of critical substances in battery cell production, as well as compliance with regulatory requirements.

Solution / Implementation:
Conducting workshops and training sessions, evaluating facilities and processes with regard to containment requirements, and developing suitable protection and safety concepts.

Your Benefits:

• Ensuring defined OEB levels and compliance with regulatory requirements
• Increased plant and process safety when handling critical materials
• Foundation for certifications and safe plant operation

Factory Acceptance Test (FAT)

Customer requirement:
Ensuring system functionality and production readiness prior to commissioning, as well as minimizing risks during ramp-up.

Solution / Implementation:
Conducting functional tests, simulations, and validations under realistic conditions, as well as creating test plans, checklists, and performance records.

Your Benefits:

• Early identification of errors and opportunities for optimization
• Reduced rework and faster commissioning
• Greater production reliability and quality during series production ramp-up