The client had anew, innovative lead acid battery design that incorporated significantly different components than a traditional lead acid battery. The uniqueness of this design required that new manufacturing methods be developed to build this product.
Project Information
Product: Lead Acid Battery Plates
Industry: Energy / Automotive / Transportation
Key Technologies: Liquid and Powder dispensing and mixing, Dipping, Robotics, Continuous Motion, Material Drying, Ultrasonics, Liquid level control
Background Information
When Belcan’s Automation Group was contacted, the manufacturing process was still lab based and very low volume
In order to manufacture this product at high volumes and consistency, new, creative processes had to be applied
This startup company did not have the engineering or manufacturing staff required to quickly launch the development effort needed to create the manufacturing systems that were required
Belcan Automation Approach
Since this was a completely new product that had only been made in a lab environment, it was determined that a disciplined phased approach needed to be implemented
The plan that Belcan put before the client included the following:
Conduct a rigorous requirements definition phase
Generate concepts that meet the program / product
requirements
Identify proof of principle projects to test processes and
technologies and reduce the risk of building a capital intense
manufacturing system
Solution
A phased approach was implemented
Belcan’s technical team worked with the client’s product, manufacturing, and management team to conduct a rigorous requirements definition session. The results of which were used to the create process concepts.
Belcan designed and built a proof of principle system that allowed the client to test a unique technology for this application and develop the manufacturing process parameters
In parallel to the process development phase, Belcan proceeded to design and build the high speed manufacturing system, based on the results of the requirements definition work
Throughout the entire process, Belcan and the client were in
close communication, sharing progress with each other on the
design and the process development work
Benefits to Client
The client was able to quickly supplement its technical product development staff with an experienced engineering team capable of supplying practical ideas to manufacture their unique product
The requirements definition phase enabled the team to quickly select the technologies with the highest probability of success to test and develop the manufacturing process around
By parallel processing the efforts of process development and system design and build, the entire equipment development cycle was reduced
The resultant production system significantly increased the manufacturing capacity of the client
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