electrochem capabilities ?· - lean manufacturing systems - continuous improvement initiatives...
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1. Who Is Electrochem?
2. Powering Critical Applications
3. Operational Excellence
4. Looking Forward
5. Electrochem: Partner of Choice
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Who Is Electrochem?
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What We Do
Electrochem is the premium provider of custom battery solutions to niche applications with high energy requirements operating in extreme environments
where the cost of failure is significant.
Electrochem designs and manufactures primary lithium cells and battery packs; secondary battery packs; and battery chargers.
Enhancing lives worldwide by providing superior power solutions that enable the success and
advancement of our customers critical applications.
A Value Add, Power Solutions Partner
We Are a Power Solutions Company
We understand our customers and their markets, partnering to bring your designs to life.
Market drivers Unmet end-user needs Product materials and design challenges Organizational structure and product development processes
We Add Value to Your Business
We help our customers build products, that emphasize safety and reliability, for applications where battery failure is not an option.
Quality focused manufacturing Technology advancements Security of supply
Electrochem Core Competencies
1. Experience- 40+ years experience with critical battery applications- Extensive battery chemistry knowledge and fundamentals, including proprietary electrolytes and a
variety of cathode chemistries
2. Quality & Reliability- Failure is not an option- Multi-discipline product development teams applying DfX principles and other risk mitigation tools- Comprehensive product/process qualifications and validations
3. Technological Innovation- Wide Range Batteries: Low temperature deck check capabilities and improved inventory control- High Temperature Batteries: Pushing temperature limits beyond 200C
4. Culture of Continuous Improvement- Lean manufacturing systems- Continuous improvement initiatives leveraging Six Sigma methodologies
5. Safety & Compliance- Numerous global certifications and compliance measures (ISO, UL, CE, IATA, DGR, TCC)- Fail-safes incorporated into all battery pack designs ensuring user safety
Electrochem, an Integer Company
Integer is one of the worlds largest medical device outsource manufactures, delivering revenues approaching $1.4B annually with numerous locations throughout the world.
Electrochem operates as an Integer company, part of Integer at the highest level, while maintaining independent leadership, processes, and decision making. Our heritage for superior quality, reliability, and innovation are part of our DNA; deeply rooted from our origins when Wilson Greatbatch invented the battery for the first implantable pacemaker.
Electrochem is uniquely positioned to benefit from this structure. We have the ability to leverage the extensive resources of Integer when needed, while maintaining the flexibility to operate independently. This allows us to have the stability and influence of a larger company with the focus and agility of a smaller one.
Where Were Located
Our Operations Raynham, MAFacility: 82,000 sq ft,, expandable to 122,000 sq ft, (owned)Staffing: 260 Associates Current Utilization: 2 Shifts, 5 days x 8 hour shift (>70%)Regulatory: ITAR, DHS, PSM, 21CFR Section 820 Quality System: ISO9001:2008, ISO13485:2012, FDA RegisteredTechnical Capabilities: Primary lithium cell technology, Cathode & Electrolyte technologies, Battery pack assembly techniques, IPC610 soldering, laser welding & marking, glass-to-metal seals, ultrasonic & resistance welding, robotic assy.
Primary Cells & Battery Packs
Secondary Battery Packs
Secondary Battery Chargers
Complete primary battery production, from cell manufacturing through final pack assembly and testing
Vast portfolio of technical capabilities, intellectual capital, and industry experience ensuring the ability to meet all project requirements
Eagle Eye Program: Associate engagement program designed to drive a zero defect safety & quality culture
Fortified infrastructure (room within a building) and automated event isolation chamber system ensuring operational safety and continuity
Includes advanced R&D, rapid prototyping, and testing laboratories
Highly secured and controlled environments for protection of our people and products
Designed to embrace a Lean Enterprise and Six Sigma approach across all activities
Business sensible green building
Security of Supply
Business Recovery Plan: In the event of a disaster or catastrophic event, a comprehensive business recovery plan is maintained; critical, redundant equipment is stored offsite for expedited resumption of full production
Supplier Management Process: Ensures the uninterrupted flow of incoming materials and required services
Risk Assessments: Regularly conducted to ensure adequate controls are in place and all potential scenarios are evaluated
Designed-in safety controls and redundant facility infrastructure
Powering Critical Applications
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The Leader in Battery Solutions for Critical Applications
Marine Seismic Surveying
Communications & Surveillance
Avionics & Sensors
Detection & Monitoring
Primary Battery Packs
Secondary Battery Packs
Secondary Battery Chargers
Primary Battery Technology
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Electrochem makes a broad range of sizes and types of cells
Rate Capabilities Temperature Ranges Typical Capacities
Low RateMemory back-up
Moderate RateDown hole power (current industry
High RatePipeline inspection, seismic surveying,
oceanographic, aerospace, etc.
< 100C PIG, military/aerospace, oceanographic, etc.
< 150C Majority of Oil & Gas drilling
< 165C Oil & Gas drilling
< 180C Deep Oil & Gas drilling
< 210C Ultra-deep Oil & Gas drilling
Thionyl Chloride (SOCl2) Widely used in downhole market Excellent performance at high temperatures Open circuit voltage = 3.67 V
BCX (SOCl2 with BrCl additive) Enhanced performance and safety at very low
temperatures Developed for use on Space Shuttle missions,
also used in oceanographic applications Open circuit voltage = 3.9 V
Sulfuryl Chloride, or CSC (SO2Cl2) Highest energy density Best performance is obtained at moderate
temperatures, but also used in some high temperature downhole applications
Open circuit voltage = 3.93 V
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Bobbin design: simple and rugged
Small cell sizes, memory back-up and similar applications
Moderate Rate Dual Anode
Modified bobbin design with second layer of anode: simple & rugged, but higher rate capability
The workhorse of Electrochems downhole offerings: in widespread use for more than 25 years
High Rate Spiral
Higher surface area electrodes
Ruggedized designs (MWD, WR) can withstand downhole shock & vibration
High rate cells include an inaccessible external fuse
Custom Pack Examples
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Energy MWD/LWD Operations Energy Pipeline Inspection
Environmental Subsea Surveillance Military Primary Power
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Quality Systems / CI Focus
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Quality System Controls
NPI / Production
Quality System Controls Change Management Risk Management Validation Spec Concurrence Product Development Process Equipment Management Process Control Training
Monitoring Nonconformance Management Gate Calls Customer Feedback and Complaints Production Data and Trending Equipment Performance Operational Efficiency Internal Audits
Improvement Corrective Action Kepner-Tregoe Projects Quick Fixes Eagle Eye Program Kaizen
Behavioral Based Safety Program
Observation based program promoting proactive safe behavior before incidents, or near misses, occur.
Associates are trained to observe peers and provide immediate, effective, safety feedback. Observations are c