Projects

Stabilizing High-Speed Laser Systems in Battery Cell Production

How we eliminated recurring failures in a critical cooling system and ensured more than three years of reliable operation across 45 production machines.

Context

A leading automotive manufacturer relied on a high-speed battery cell production line where laser cleaning systems played a critical role in the coating process.

Challenge

A recurring failure within the laser cooling system caused water leakage onto the production line approximately every three weeks. The issue resulted from continuous movement, heat, smoke exposure, and demanding operating conditions, creating maintenance challenges and reducing production reliability.

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Solution

We performed a root cause analysis and redesigned a critical cooling system component to withstand the harsh production environment. The new design significantly improved durability and long-term operational stability.

Result

The redesigned component has now been operating reliably for more than three years without recurring failures.

Following the successful implementation, the solution was standardized across 45 production machines, improving system reliability while significantly reducing maintenance interventions and production disruptions.

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Project impact

Industry
Automotive Battery Manufacturing

Expertise
Mechanical Engineering & Reliability Optimization

Challenge Solved
Recurring Cooling System Failures

Business Impact
3 weeks → 3+ years operational reliability
45 production machines successfully upgraded

Consulting

Services

Commercial & Marketing Consulting

Dr. Noémi Farkas
  • marketing and brand positioning
  • business process support
  • commercial strategies

Technical & Engineering Consulting

Dr. Benjamin Bär
  • technical & engineering consulting
  • quality assurance and product quality
  • AI consulting and prompt consulting
  • lean and Six Sigma methodologies
  • urban air technology
  • logistics
  • Industrial 5.0 solutions