electrochem capabilities · - lean manufacturing systems - continuous improvement initiatives...

Electrochem Capabilities

Agenda

1. Who Is Electrochem?

2. Powering Critical Applications

3. Operational Excellence

4. Looking Forward

5. Electrochem: Partner of Choice

2 Electrochem Confidential

Who Is Electrochem?


Electrochem Confidential

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.

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Our Vision

Enhancing lives worldwide by providing superior power solutions that enable the success and

advancement of our customers’ critical applications.

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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

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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 200°C

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

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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.

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Global Footprint

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Where We’re Located

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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.

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Product Capabilities

• 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

State-of-the-Art Facility

• 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



The Leader in Battery Solutions for Critical Applications

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Energy

• Downhole Drilling

• Pipeline Inspection

• Marine Seismic Surveying

Military

• Communications & Surveillance

• Avionics & Sensors

Environmental

• Oceanographic Systems

• Detection & Monitoring

• Industrial/Utility


Solutions

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Primary Cells

Primary Battery Packs

Secondary Battery Packs

Secondary Battery Chargers

Primary Battery Technology


PacksCells


Cells

Electrochem makes a broad range of sizes and types of cells

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Rate Capabilities Temperature Ranges Typical Capacities

Low RateMemory back-up

Moderate RateDown hole power (current industry

standard)

High RatePipeline inspection, seismic surveying,

oceanographic, aerospace, etc.

< 100°C PIG, military/aerospace, oceanographic, etc.

AA 1.5Ah

C 6.0Ah

D 12Ah

CC15Ah

DD 29Ah

TSD 40Ah

< 150°C Majority of Oil & Gas drilling

< 165°C Oil & Gas drilling

< 180°C Deep Oil & Gas drilling

< 210°C Ultra-deep Oil & Gas drilling

Cell Chemistries

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



Cell Construction

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Low Rate

• 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 Electrochem’s 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


Energy – MWD/LWD Operations Energy – Pipeline Inspection

Environmental – Subsea Surveillance Military – Primary Power

Operational Excellence


Quality Systems / CI Focus


Plan

Quality System Controls

Do

NPI / Production

Check

Monitoring

Act

Improvement

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


Safety-Based Culture

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 collected and shared anonymously with all associates to promote

continuous improvement.• The goal is for safe behavior to become “second nature” for all associates.

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The Eagle Eye Program

• An associate driven feedback process focusing on facility quality & safety improvements.

• Any associate can submit an Eagle Eye suggestion.• Associates who submit Eagle Eye suggestions have the opportunity to

select a small award for their contribution to improve quality and safety.• Each quarter, a group of associates is presented with the “Soaring

Eagle” award for the most active participation that positively impacted quality and safety.


Regulatory Compliance

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Monitor compliance to all applicable regulations and industry standards• STP update subscriber• ICAO, IATA, UN, DOT, FAA• UL, IEC• OSHA• RoHS, REACH, WEEE• Conflict Minerals

Battery industry leading SME• NEMA & PRBA battery council member• Industry representative to government agencies and dangerous

goods panels• Educate regulators• Provide input into proposed regulations

http://www.google.com/url?sa=i&source=images&cd=&cad=rja&uact=8&ved=0CAgQjRw&url=http://en.wikipedia.org/wiki/File:IATA_Logo.svg&ei=ml30VP7eHsGLgwTflIP4Ag&psig=AFQjCNGs6OfU7BYVs71oD4BOqqi4hBlJkA&ust=1425387290569773


Lean Enterprise

Lean Center of Excellence (COE)• Business and operations process optimization driven by Hoshin plan

Synchronization • Drive standard processes and best practices across the enterprise

(lean, supply chain, finance, etc)

Supplier Development• Work directly with supply base to reduce costs, reduce lead time,

improve delivery/performance

Greatbatch Production System (GPS)• Comprehensive production system deployment

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Product Lifecycle Management

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Conceive

Plan / Design / Develop

Service

Realize

Verify

Dedicated project manager

facilitates the assigned cross-

functional team through the

design and development steps

Qualifications and

Validations completed &

documented

Production transfer and

scale-up

Technical Support, Global Site Support,

Sustaining Engineering Activities

including material obsolescence & EOL

Management

Project requirements and

specifications defined


Custom Pack Development Process

NPI Development Cycle: 6 – 18 Months

Build To Print Development Cycle: 4 – 6 Months

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PlanningDesign Inputs

Design Outputs

Verification &

Validation

Scale Up & Transfer

Looking Forward



Portfolio Investments

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Wide Range Technology

• Simplifies inventory controls: One battery can support multiple temperature ranges.

• Improves efficiency: Reduced need for “trip outs” as temperatures change downhole .

• Improves safety & reliability: Allows for safe testing of downhole tools at surface temperatures, before they go downhole.

High Temperature Technology

• Improves data quality: Allows for the use of battery power at temperatures above 200C, removing the signal noise created by traditional power sources.

• Added confidence: High Temperature batteries enable the continuous backup of data if the drill ever needs to stop.

Under Voltage Protection Circuit

• Prevents Over Discharge: Disconnects load when voltage drops below an acceptable limit, reducing the chance of a costly, possibly dangerous, cell vent situation.

• Prevents Voltage Reversal: Eliminates the risk of a cell being driven into voltage reversal from the other cells connected in series, further reducing the possibility of a cell vent.

Electrochem: Partner of Choice



Electrochem Delivers

1. Security of Supply• Robust systems to proactively assess, mitigate, and control risk and ensure an

uninterrupted supply of products to customers.

2. Complete Customer Support• Fast and effective customer support including dedicated consult and design teams with

years of industry experience.

3. Unmatched Performance• Superior performance in terms of reusability, discharge rate, and low temperature

operation.

4. A Trusted Partner• As a primary supplier to top companies across numerous industries, we maintain strict

confidentiality to protect our customers.

5. Industry Leading Quality & Reliability• Provider of the safest, highest quality, battery solutions available in the markets we serve.

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Thank You


electrochem capabilities · - lean manufacturing systems - continuous improvement initiatives...

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