KPI

Cluster-KPIs

OEE(Overall Equipment Effectiveness)-Potential

$Availability\times Performance\times Quality$

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

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

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

Current estimated OEE:

• Availability = 77,82 %
• Performance = 72,98 %
• Quality = tbd

→ $77,82\%\times 72,98\%\times tbd=$

Target OEE:

• Availability = 77,82 %
• Performance = 72,98 %
• Quality = tbd + x%

→ $77,82\%\times 72,98\%\times tbd=$

Quality

Product requirements and specifications

• Energy density, gravimetrically in Wh/kg and volumetrically in Wh/l
• Power density, gravimetrically in W/kg and volumetrically in W/l
• Service life, operating service life in cycles and calendar service life in years
• Environmental conditions or acceptable maximum and minimum temperatures in °C
• Efficiency in percent

TCO-Potential

TCO = Acquisition costs + Personnel costs + Energy costs + Maintenance costs + Downtime costs + Running costs (e.g., training courses) + Opportunity costs + Costs for operating materials + Disposal costs + Energy efficiency + CO2 balance

Saving potential energy costs:

• Forming process: The forming process accounts for approx. 9.4 % of the energy costs in the processes considered (packaging to forming).

Current estimated TCO:

• Current energy consumption of forming process: 15 Ah per 870 mAh cell

Target TCO:

• Reduction of energy consumption in the forming process by 20 % results in a reduction of total energy costs by approx. 2 % ($20\%\times 9.4\%$)

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)

Current electrolyte consumption:

• 4 ml per 870 mAh cell

Target electrolyte consumption:

• 3.5 ml per 870 mAh cell

Energy consumption per unit

The energy consumption per unit can be reduced by optimizing the forming process.

Current energy consumption:

• 15 Ah per 870 mAh cell

Target energy consumption:

• 12 Ah per 870 mAh cell

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Variable production costs

The variable production costs are composed of the energy, material, scrap and manufacturing costs.

Current variable production costs:

• 100%

Target variable production costs:

• 90%

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)