electrochem capabilities · – lean manufacturing systems ... (iso, ul, ce, iata, dgr, tcc) ......
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Electrochem confidential. Not for distribution.
Electrochem Capabilities
Electrochem confidential. Not for distribution.
Who Is Electrochem?
Electrochem confidential. Not for distribution.
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.
Electrochem confidential. Not for distribution.
Our Vision
Enhancing lives worldwide by providing superior power solutions that enable the success and advancement of
our customers’ critical applications.
Electrochem confidential. Not for distribution.
A Value Add, Power Solutions Partner
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 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
We Are a Power Solutions Company
We Add Value to Your Business
Electrochem confidential. Not for distribution.
Electrochem Core Competencies
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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
Electrochem confidential. Not for distribution.
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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 first lithium battery for implantable pacemakers.
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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Electrochem confidential. Not for distribution.
Global Footprint
Electrochem confidential. Not for distribution.
Where We’re Located
Clarence, NYSales, Marketing Raynham, MA
Operations, Sales
Tampa, FLSales
Houston, TXSales
Physical Office
Remote Office
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New Haven, CTSales
Electrochem confidential. Not for distribution.
Our Operations
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
Facility: 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 Registered
Technical 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.
Raynham, MA
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Electrochem confidential. Not for distribution.
Powering Critical Applications
Electrochem confidential. Not for distribution.
The Leader in Battery Solutions for Critical Applications
Energy
• Downhole Drilling
• Pipeline Inspection
• Marine Seismic Surveying
Military
• Communications & Surveillance
• Avionics & Sensors
Environmental
• Oceanographic Systems
• Detection & Monitoring
• Industrial/Utility
Electrochem confidential. Not for distribution.
Solutions
Primary Cells
Primary Battery Packs
Secondary Battery Packs
Secondary Battery Chargers
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Electrochem confidential. Not for distribution.
Primary Battery Technology
PacksCells
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Electrochem confidential. Not for distribution.
Cells
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
Electrochem makes a broad range of sizes and types of cells
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Electrochem confidential. Not for distribution.
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
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Electrochem confidential. Not for distribution.
Cell Construction
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
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Electrochem confidential. Not for distribution.
Custom Pack Examples
Energy – Downhole Operations Energy – Pipeline Inspection
Environmental – Subsea Military – Primary Power
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Electrochem confidential. Not for distribution.
Operational Excellence
Electrochem confidential. Not for distribution.
Quality Systems / CI Focus
Plan
Quality System Controls
Do
NPI / Production
Check
Monitoring
Act
Improvement
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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• Kaizenc
Electrochem confidential. Not for distribution.
Safety-Based Culture
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.
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.
Behavioral Based Safety Program
The Eagle Eye Program
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Electrochem confidential. Not for distribution.
Regulatory Compliance
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
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Electrochem confidential. Not for distribution.
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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Electrochem confidential. Not for distribution.
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
Electrochem confidential. Not for distribution.
Custom Pack Development Process
PlanningDesign Inputs
Design Outputs
Verification &
Validation
Scale Up & Transfer
NPI Development Cycle: 6 – 18 Months
Build To Print Development Cycle: 4 – 6 Months
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Electrochem confidential. Not for distribution.
Electrochem: Partner of Choice
Electrochem confidential. Not for distribution.
Electrochem Delivers
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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.
Electrochem confidential. Not for distribution.
Thank You