PRODUCTION QUALITY OF ADVANCED LABS FULFILLING THE ZERO FAILURE APPROACH AABC EUROPE 2017 CHEMISTRY & MATERIALS FOR LEAD-BASED BATTERIES

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1 PRODUCTION QUALITY OF ADVANCED LABS FULFILLING THE ZERO FAILURE APPROACH AABC EUROPE 2017 CHEMISTRY & MATERIALS FOR LEAD-BASED BATTERIES Andreas O. Stoermer I

2 REQUIREMENTS OEMs are forcing concurrent requirements for advanced lead acid batteries as high capacity 105 Ah AGM for more consumers high discharge current 950 A for better cranking high charging current dca(t) with high t high cycle number DoD 17.5% and 50% and others partial state of charge 75% SOC light weight less lead low costs less lead, cheaper separators, cheaper/less valves different applications engine / rear at wide temperature range hot / cold standardized design acc. to EN / VDA / which are leading to the implementation of innovations to advanced lead acid batteries. AABC europe 2017 R&D Symposium 5 A.O.Stoermer Page 2

3 THE PROMISE At the end the technical sales team gives the promise to the customer to fulfill the spec. There the problem may start for all: Can you deliver what you promised with every single battery? How to proof good quality without fully testing the battery? AABC europe 2017 R&D Symposium 5 A.O.Stoermer Page 3

4 PRODUCT DESIGN QUALITY The success of any battery design starts with its product design: Requirement specification ( Lastenheft ) R&D input Lessons learnt from field returns (warranty, break downs) final customer input KPIs in production (scrap rates, OEE, ) manufacturing input requalification (stability of product/process performance) direct customer input design FMEA At the end the battery has to be designed to manufacture. How to ensure all inputs successfully implemented? House of quality (QFD* matrix) design handbook * Quality Function Deployment AABC europe 2017 R&D Symposium 5 A.O.Stoermer Page 4

5 PROCESS DESIGN QUALITY The battery performance can only be guaranteed when a high process quality is ensured. As the battery cannot be fully tested after production because of costs and the behavior of lead acid batteries itself, process design has to be on highest level (ref. process FMEA). Full QFD approach can ensure a production design to quality Examples for lead acid batteries where process design quality matters: Lead oxid production (Barton or ball mill) pasting process (different possibilities) filling process for AGM batteries (modern computer aided process development tools as CAD-FEM / Fluent may be used for the process design) Subsuppliers for the equipment (machinery, technologies, reliability, maintenance) Mostly the process design is heavily influenced by historic facts not by new approach. AABC europe 2017 R&D Symposium 5 A.O.Stoermer Page 5

6 PROCESS STABILITY Once the process is designed and established, it has to be stable. Although product and process designed carefully and according to best practice and due diligence, processes have to be maintained. Besides process control of each process, total preventive maintenance and Kaizen production processes have to be controlled online and instantly. Even small deviation can lead to severe product weakness, so online- SPC tools with immediate reaction protocols of men/machine has to be applied. This stabilizes not only the quality of the product, it also helps to readjust processes and reduce costs (scrap, ressources, OEE, machine time). The human factor shall be minimized to an absoult minimum the process planner is responsible for mistakes, not the operator! SQA shall also check the incoming materials frequently. AABC europe 2017 R&D Symposium 5 A.O.Stoermer Page 6 Change management at the suppliers has to be enabled and secured.

7 0-REWORK APPROACH In automotive industry there have been different approaches how to deal with quality deviations but time chances. In principle different Lead Acid Battery designs allow rework. Some does not. And even if so: you never know the influence (even if QFD applied). From quality mindset approach rework has to be avoided anyway at any product. Why? Rework which has been evaluated (cpk!), validated and released always has higher costs than doing the process right at the first time. Allowing unnecessary rework means limiting the motivation to fix the problem. Only consequent usage of QRQC* and DMAIC** makes you learning from deviations. * Quick Response Quality Control ** Design / Measure / Analyze / Improve / Control AABC europe 2017 R&D Symposium 5 A.O.Stoermer Page 7

8 TRACEABILITY AND PROCESS-INTERLOCK Latest international standards, company standards and product liability laws are pushing traceability: A full traceability of the production process and the material flow is a strong requirement Not only the process data shall be documented to each battery, also the incoming materials like oxide batch, acid batch, plastic batch of lid and housing as the separator data shall be connected to each battery. Furthermore a traceability system realized by a ID (e.g. DMC) on the product itself gives the change to interlock processes and control minimum and maximum times between process steps. For AGM batteries the big suppliers are fulfilling these requirements perfectly. Furthermore, the battery ID is connected to the customers ID on the battery label. AABC europe 2017 R&D Symposium 5 A.O.Stoermer Page 8

9 SUMMARY The promise of 100% quality for every single battery can be only ensured by your commitment to Product Design Quality Process Design Quality Process Stability 0-Rework Approach Traceability and Process-Interlock Fulfilling the Zero Failure Approach is not only a vision it s a mission for advanced lead acid batteries! Lithium-Ion Cells are already fulfilling the Zero Failure Approach and are the challenging benchmark. AABC europe 2017 R&D Symposium 5 A.O.Stoermer Page 9

10 CONTACT DATA ANDREAS O. STOERMER Position at BMW Group today: Purchasing and Supplier Network General Manager Quality Management Parts Alternative Powertrains Contact data: BMW Group QMP Alternative Powertrains Taunusstrasse 41, München Germany Phone AABC europe 2017 R&D Symposium 5 A.O.Stoermer Page 10

11 PRODUCTION QUALITY OF ADVANCED LABS FULFILLING THE ZERO FAILURE APPROACH AABC EUROPE 2017 CHEMISTRY & MATERIALS FOR LEAD-BASED BATTERIES Andreas O. Stoermer I