Battery manufacturing workflow
Case study 02
Less moving things around. More time building.
The challenge
Battery production was taking approximately six to eight hours per pack, depending on the operator. The work was being performed in an R&D-style space without a clear material flow, so people and components moved around the room unnecessarily.
The work
In a previous manufacturing engineering role, Jack redesigned the production layout around a one-way sequence: cell testing, pack assembly and final pack testing.
He also designed a rotating fixture for pack assembly, making it easier for technicians to access different sides of the battery without dragging it around the bench or reaching over it.
The changes focused on simplifying the physical workflow before adding complexity.
The outcome
Reported end-to-end build time fell from approximately six to eight hours to two to three hours per pack, depending on the operator.
What it demonstrates
Process automation starts with understanding the process. Sometimes the first improvement isn't software at all; it's removing unnecessary movement and making the work easier to carry out.