Productivity and Industrial Engineering (IE) in Battery Manufacturing
Lesson 439 of Industrial Engineering ONLINE Course - Applied Industrial Engineering Module
Best EBook of 2023 #IndustrialEngineering. FREE Download.
MODERN INDUSTRIAL ENGINEERING:INDUSTRIAL ENGINEERING OF PRODUCTS, FACILITIES & PROCESSES
2023
ELECTRIC VEHICLE BATTERY PACK ASSEMBLY - Case Study - JR Automation
R202335883
Industrial Engineer II - EV Battery Solutions
Full time, Day
Travel: Yes, 15% of the time
JOB CATEGORY: Engineering / Product Development
JOB LEVEL: Individual Contributor
DIVISION: Cox Automotive
LOCATION:
2084 Lake Industrial Ct, Conyers, Georgia
Description
A successful Process Engineer will use process improvement experience to quantitatively assess current production/business system performance and execute change to reduce cost and optimize capacity.
This role demands excellent communication and interpersonal skills as well as a holistic understanding of manufacturing operations.
This role will focus on creative problem solving and working cross functionally (production, design, quality, finance, supply chain, demand and production planning) to improve capacity, workstation design, and reduce downtime. A successful team member will have excellent critical and creative problem-solving skills with a focus on issue resolution and inter-department engagement.
· Oversees and assesses existing processes and workflows in place and develops SOPs
· Evaluates data to implement improvements in production processes.
· Identify, quantify, compare, and execute production process improvements to drive safety and ergonomics, quality (first pass yield), availability (uptime), performance (cycle time variability), capital utilization, and demand attainment.
· Work cross-functionally to develop and implement best practices for assembly and standard work instructions.
· Identify, propose, manage, and monitor manufacturing improvements.
· Use predetermined time standard methods to analyze and optimize current and future planned manufacturing processes.
· Create and implement tools to audit efficiency and identify cost-reduction opportunities.
· Utilizes process simulation software to test and find the most appropriate production strategies.
· Manage and communicate improvement opportunities and implementation plans to all relevant levels and functions in the factory
· Oversees and assesses existing processes and workflows in place.
· Evaluates data to implement improvements in production processes.
· Creation of reporting documentation for processing status and changes.
· Tracks metrics to discover areas for improvement and monitor upgrades.
· Provides thorough instructions for successful implementation of process changes.
· Conducts risk assessments and develops process flows, PFMEAs, and Control Plans.
· Designs facility layout and personnel requirements in relation to production operations.
· May perform other assignments as required and may travel 15 to 20 % as required.
Skills & Qualifications:
Functional understanding of Statistical Process Control (SPC).
Functional understanding of Value Stream Mapping (VSM), experience is preferred.
Functional understanding of Just-in-Time (JIT) supply chain strategy.
Knowledge of process engineering simulation software (E.g., FlexSim).
Robust knowledge of computer-based tools such as MS Office, Visio, Lucid chart, etc.
Strong Excel skills associated with data analysis.
Experience in MySQL is an added advantage.
Strong attention to detail with a proven ability to identify gaps in operational systems.
Ability to read and interpret assembly/component drawings and engineering specifications.
Demonstrated ability to assess and solve problems.
Familiarity with Environmental Health & Safety regulations.
Demonstrable communication skills:
Written
Verbal
Presentations
Education, Experience, and Licensing Requirements:
BS in industrial engineering or a related field such as manufacturing or mechanical engineering.
2-3 years of relevant work experience in a production environment.
2-3 years experience in continuous improvement activities and knowledge of Lean Manufacturing principles
Experience with industry-standard problem-solving methodologies (A3, 8D, ATS), preventive and autonomous maintenance concepts, time/motion study analysis (MODAPTS preferred), continuous improvement (6 sigma techniques, lean manufacturing), and change management
Master’s degree in engineering is a plus.
About Cox Automotive
At Cox Automotive, people of every background are driven by their passion for mobility, innovation and community. We transform the way the world buys, sells, owns and uses cars, accelerating the industry with global powerhouse brands like Autotrader, Kelley Blue Book, Manheim and more. What’s more, we do it all with an emphasis on employee growth and happiness. Drive your future forward and join Cox Automotive today!
Industrial Engineer – Battery Manufacturing
BlueOval SK, LLC · Glendale, KY 7 months ago · 29 applicants
Hybrid Full-timeMatches your job preferences, job type is Full-time. Entry level
5,001-10,000 employees · Motor Vehicle Manufacturing
1 connection works here · 1 school alum works here
Skills: Industrial Engineering, Root Cause Analysis, +8 more
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About the job
Introduction to BlueOval SK
At BlueOval SK, we will lead the transformation of the electric vehicle (EV) battery business through partnership (Joint Venture formed by Ford and SK On) to provide products and processes to increase our customers’ experience. As the future of BlueOval SK, you will help lead the battery revolution by working alongside our teams as we build the batteries required for electric vehicle business excellence.
Ford and SK On are investing billions in Kentucky and Tennessee including building three state-of-the-art battery manufacturing facilities between the two campuses at BlueOval City in Tennessee and BlueOval SK Battery Park in Kentucky. These brand-new advanced manufacturing facilities will use Ford’s 100-years of automobile manufacturing expertise and SK On’s 30+ years of electric vehicle battery expertise to become the world’s best battery manufacturer.
The Industrial Engineer at BlueOval SK Battery Park in Glendale, Kentucky will have a unique, once-in-a-lifetime opportunity to be a key member of the start-up team, launching the facility from the ground up.
Key Areas of Responsibility:
Drive development and/or installation of direct and indirect labor standards and methods.
Track labor, efficient manpower utilization and line balancing
Conduct Job Ergonomics evaluations
Analyze problem process constraints and conduct equipment cycle time analysis
Recommend most efficient distribution of manpower and review daily employee manpower, analyze plant methods and standards
Prepare or direct the preparation of cost estimates of new or revised methods and standards
Review proposed changes in plant layout, processes, material handling, routing, etc.
Analyze production and non-production operations to determine those requiring study and develop new or improved methods and standards
Conduct time and motion/MODAPTS studies and review employee proposals and suggestions
Develop cycle line layouts for current and future models using ACAD. Lead job methodization and process allocations
Coordinate engineering changes and planning. Conduct value stream mapping and process audits
Develop cost saving project proposals and write projects as required
Assist production in planning labor allocations for mix and line speed changes
Minimum Requirements:
Experience:
Must possess the ability to analyze and resolve issues quickly through route cause analysis and drive change back to the production departments. Must have the necessary skill set to have job placement flexibility and the expectation to rotate to various positions within the plant such as Production or Quality
Must display strong customer orientation with a commitment to upholding plant processes through strict adherence to the Quality Operating System.
Must demonstrate the ability to execute to achieve results, while organizing and managing multiple priorities
Must have the ability to serve as a strong and confident technical mentor to the production organization (both hourly and salary)
Must have strong written and verbal communications skills
Ability to support any shift in a 7-day work pattern
Candidate must be flexible to significant travel during initial plant start-up phase
Candidate must be willing to work remotely and in-person at temporary facilities as needed during initial plant start-up phase
Successful candidate must be able to demonstrate leadership behaviors consisting of outstanding interpersonal, teambuilding, and communication skills
Preferred Requirements:
Education: Bachelor’s Degree in Industrial Engineering
Experience: 3-5 years’ experience
MODAPTS Certification
GSPAS knowledge
About BlueOval SK
At BlueOval SK, we will lead the transformation of the electric vehicle (EV) battery business through partnership (Joint Venture formed by Ford and SK On) to provide products and processes to increase our customers’ experience. As the future of BlueOval SK, you will help lead the battery revolution by working alongside our teams as we build the batteries required for electric vehicle business excellence. We have a wide variety of opportunities for you to accelerate your career.
Tesla - Notes taken from the Fireside Chat with Drew Baglino (SVP, Tesla Motors)
Shirley Meng, Professor at The University of Chicago, Chief Scientist of Argonne Collaborative Center for Energy Storage Science
March 28, 2023
The importance of dry electrode
DB’s insights
a. Manufacturing at SCALE requires reducing site footprint, labor cost and CAPEX cost – dry processing can enable reduction of these things by a factor of 3.
b. Dry processing can overcome the speed limit set by wet processing. A factor of 2 to 3 enhancement in manufacturing speed is possible, for example, 200-300m/min production speed is possible.
c. Single percentage yield improvement matters now because the metal prices (Li, Ni, Co) are going up. This is important that the yield of dry process continues to improve.
Lithium IOn Batter Cost components - picture in a linkedIn post
2012
The production of electric cars is growing day by day. Therefore the need for batteries is also growing. Efforts are on by various entrepreneurs to create capacity for battery manufacturing. Industry associations have come up and are doing their bit to put in place in environoment, systems and procedures so that profitable industry emerges.
Industrial engineering profession has to set up its own organization to study and introduce industrial engineering principles, methods and tools into the upcoming advanced battery industry right from the design stage of products and production systems.
2012 Symposium on Building the US Battery Industry for Electric Drive Vehicles
http://www.nap.edu/openbook.php?record_id=13370
McKinsey on Battery Prices and Costs - 2012 Analysis
Our analysis indicates that the price of a complete automotive lithium-ion battery pack could fall from $500 to $600 per kilowatt hour (kWh) today to about $200 per kWh by 2020 and to about $160 per kWh by 2025. In the United States, with gasoline prices at or above $3.50 a gallon, automakers with batteries at prices below $250 per kWh could offer electrified vehicles competitively, on a total-cost-of-ownership basis, with vehicles powered by advanced internal-combustion engines. Any further decrease in battery prices and increase in gasoline prices could tilt the balance in favor of electric vehicles.
http://www.mckinsey.com/insights/energy_resources_materials/battery_technology_charges_ahead
http://naatbatt.org/naatbatt-blog/engineering-vs-materials-science-in-advanced-batteries/
April 2012
An all-electric vehicle needs the battery size of around 23 kilowatt hours.
That size batter is priced around $12,000 to $15,000 a battery. The price of a gasoline-powered Focus (Ford) is about $22,000. Ford is currently promoting its $39,200 Focus Electric car.
Based on the indicated price range for the battery we estimate that Ford is paying between $522 and $650 a kilowatt-hour for its electric-vehicle batteries.
The U.S. Department of Energy, as part of its efforts to help promote plug-in hybrid- and fully-electric vehicles, has set a goal of lowering the cost of batteries to $300 a kilowatt-hour by next year (say start of 2014)
http://online.wsj.com/articles/SB10001424052702304432704577350052534072994
2015 and 2020 targets set by USA Government
http://gas2.org/2012/01/25/the-dropping-price-of-the-ev-battery/
Assembly Technology Improvements in Battery Manufacturing - April 2013
January 2014
Have the prices of batteries dropped already - Discussion
http://cleantechnica.com/2014/01/07/ev-battery-prices-much-lower-think/
February 2014
Mahindra Reva introduced an eletric car battery rental scheme and dropped its price by Rs. 1.7 lakh. Against earlier 6.5 lakh, the car is now available at 4.99 lakh. The battery rent is 2,599 per month for 800 Km per month.
http://www.autocarindia.com/auto-news/mahindra-reva-introduces-new-scheme-drops-e2o-prices-372718.aspx
Mahindra Reva's power is 14.8 KW at 3000 rpm and it uses 48 V battery.
http://mahindrareva.com/product/specifications
September 2014
Sakti 3 is coming with solid state lithium ion battery. It is planning to come out with commercial application.
Toyota is also making efforts to come out with solid state L-i battery
http://fortune.com/2014/09/18/sakti3-lithium-ion-battery/
Tesla Motors to set up $5 billion electric car battery plant to produce battery that will power 500,000 cars in year. It will be equal to 50 gigawatt hours per year.
http://fortune.com/2014/09/05/details-emerge-about-teslas-nevada-gigafactory-deal/
Ud. 4.12.2023, 20.11.2023
Pub. 14.11.2014
