Case Study: 18 Months of high Scrap. The problem wasn't where they were looking.

A battery manufacturer had seen 18 months of high scrap.  The Voltaiq Tiger Team traced manufacturing defects upstream to specific lots of an input material — helping the manufacturer reach 90%+ yield. 

This customer had been dealing with stubbornly high scrap rates for 18 months. Defects — including delamination, poor coating quality and flaking — appeared to stem from assembly issues. Hundreds of process parameters were investigated, but there was no clear root cause and the problem persisted.

Voltaiq connected data across electrode fabrication, slurry preparation, cell assembly and test, giving the team a complete overview of the production history. By analyzing hundreds of process variables together, a clear pattern emerged.

Defective cells traced back to certain lots of conductive additive, causing slurry non-uniformity. 

The manufacturer implemented new incoming inspection procedures and optimized slurry and mixing process tolerances. As a result, they achieved 90%+ yield and an estimated $100M+ in additional yearly revenue.