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
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
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.
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).
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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
- Recorded data points: 80%, improvement by 54%
- Automatically assigned data points: 40%, improvement by 74%
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. Failed to parse (Conversion error. Server ("cli") reported: "SyntaxError: Expected "-", "[", "\\", "\\begin", "\\begin{", "]", "^", "_", "{", "}", [ \t\n\r], [%$], [().], [,:;?!'], [/|], [0-9], [><~], [\-+*=], or [a-zA-Z] but end of input found.in 1:108"): {\displaystyle \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)
