KPI

Cluster-KPIs

OEE-Potential

The KIproBatt project aims at increasing the Overall Equipment Effectiveness (OEE) by improving the quality factors:

• Reduction of scrap parts
• Reduction of reworking parts
• Integration of real-time sensor data

$OEE=Availability\times Performance\times Quality$

$Availability={\frac {\text{actual production time}}{\text{possible production time}}}\times 100$

$Performance={\frac {\text{actual output}}{\text{possible output}}}\times 100$

$Quality={\frac {\text{flawless products}}{\text{actual output}}}\times 100$

Base value

The base value for the laboratory battery production process is to be determined on the basis of the first battery batch produced (approx. 50 batteries).

$Quality={\frac {\text{no. produced parts - (no. rework + no. scrap)}}{\text{no. produced parts}}}$

Current state

No improvement achieved yet, as laboratory battery production has not yet started.

Target value

The quality parameter should be increased by approx. 5%.

TCO-Potential

The KIproBatt project aims at decreasing the Total Cost of Operations (TCO) by improving the subsequent factors:

• Reduction of energy consumption
• Cost of operating materials (e.g., reduction in the use of operating materials, avoidance of waste)
• Integration of real-time sensor data

Base value

The base value for the laboratory battery production process is to be determined on the basis of the first battery batch produced (approx. 50 batteries).

Current state

By using the reference process in the forming process, the energy consumption and the associated energy costs are already reduced compared to the original process. Energy consumption is thus reduced by approx. 2% (20% reduction in energy consumption in the forming process, 9.4% share of forming in total energy consumption).

Target value

The TCO should be decreased with respect to two factors:

• Reduction of energy consumption by approx. 5%.
• Reduction of costs of operating materials by approx. 5% (see 3^rd Project-KPI)

Project-KPIs

Material consumption per unit

Models can be used to estimate the amount of electrolyte required and to reduce it. In contrast to the active material, a greater potential for reduction is seen here, since the active material has a direct influence on the energy content of the cell. → Contributes to the reduction of production costs (not listed in OEE/TCO).

Base value

Electrolyte consumption of 4 ml per 870 mAh cell

Current state

No improvement achieved yet, as laboratory battery production has not yet started.

Target value

The material consumption per unit should be reduced to by approx. 12.5%. The target value for electrolyte consumption is 3.5 ml per 870 mAh cell.

Share of digital interfaces

The KIproBatt project aims at increasing the share of digital interfaces that are integrated in the production process. This share is measured by combining two factors:

• Share of data points that are recorded for a single cell.
• Share of data points that is assigned to a single cell without human intervention (automatically).

${\text{KPI2}}={\frac {\text{no. recorded data points}}{\text{no. considered parameters}}}\times {\frac {\text{no. assigend data points}}{\text{no. considered parameters}}}$

Base value

The base value stems from the data point assessment prior to installation of additional sensors and the total number of data points included in the project's process impact matrix.

• Recorded data points: 52%
• Automatically assigned data points: 23%

Current state

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	Fraunhofer ISC/Processes/KIproBatt v1
Total Parameters	54
Unrecorded Parameters	5
Recorded Parameters	47
Manually Recorded Parameters	12
Automatically Recorded Parameters	35
Recorded/Total	87 %
Automatically Recorded/Total	65 %

KPI2 = 0.56

Target value

• Recorded data points: 92%
• Automatically assigned data points: 90%

Variable production costs

Production costs are made up of several variable costs. In the context of the project, the energy, material, scrap and manufacturing costs are considered. ${\text{KPI3}}={\frac {\text{total var. production costs}}{\text{costs for flawless batteries}}}$

Base value

The base value stems from the assumption of having 10% scrap products (KPI 3 ≈ 1.11). The base value for the laboratory battery production process is to be determined on the basis of the first battery batch produced (approx. 50 batteries).

Current state

No improvement achieved yet, as laboratory battery production has not yet started.

Target value

The variable production costs should be reduced by approx. 5% (KPI 3 ≈ 1.05).

Literature

Rao et al.: Enhancing Overall Equipment Effectiveness in Battery Industries through Total Productive Maintenance, International Journal of Engineering Research in Mechanical and Civil Engineering (2017)

Pettinger, K.-H.; Dong, W.: When Does the Operation of a Battery Become Environmentally Positive? Journal of The Electrochemical Society 164 (2017)