Risk management for new battery systems

Schulz Engineering analysed the production processes for the new round cell battery systems of AKASOL AG in Darmstadt using the FMEA process. To do this, the certified FMEA moderators accompany the development of the production process from CAD concept to SOP.

AKASOL AG from Darmstadt is a leading German manufacturer of high-performance lithium-ion battery systems. Schulz Engineering took over the failure mode and effects analysis as part of the risk and process management. FMEA is used to optimise products or production processes, to avoid additional costs and to make work processes more efficient and effective. The certified moderators prepared the risk assessment for the production facilities of the “UHE” projects, both for the battery module and the battery system, according to the latest VDA/AIAG standard.

The failure mode analysis of the planned production processes was carried out in cooperation with experts from product development, plant planning, quality, testing, production, work preparation and logistics. This analysis shows potential errors in the process as well as their consequences and causes. The focus is on determining and avoiding possible causes to minimise the risk of error. After conducting the initial risk assessment, the team improved the various aspects of the production process identified as weaknesses by adjusting the prevention and detection measures.

The project is currently in the implementation phase with the Schulz Engineering measures derived from the analysis. The project will be further supervised within the framework of the FMEA coordination contract. This involves the regular review of production development and the corresponding assessment of current risk using the FMEA process.

Schulz Engineering, headquartered in Ravensburg Erlen, is one of eight subsidiaries of the Schulz Group, a medium-sized group of companies with approximately 300 employees throughout Germany, which has been successfully active in the three business areas of engineering, mechanical engineering and software for over 35 years.

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