Case Study | Automotive Battery Manufacturing Automation
Less Equipment. Lower Cost. More Output.
They Asked for a Copy. PMi2 Built a Better System.
An international automotive battery manufacturer needed to produce a critical component at its U.S. plant. The component had previously been manufactured overseas using a system designed and built in Europe. The initial plan was straightforward: ”copy and paste” the European system using U.S.-sourced parts. PMi2 proposed re-engineering the system instead of duplicating it.
PMi2 found that the system could be simplified without compromising production. The resulting design delivered 10% more output, occupied 40% less floor space, and cost less than duplicating the original system.
CEO Snapshot
10%
Higher output than the original system
Higher output than the original system
40%
Smaller footprint than the original system
Smaller footprint than the original system
100%
U.S.-sourced components. In-Line inspection
U.S.-sourced components. In-Line inspection
Lower Capital Cost
Than duplicating the original design
Than duplicating the original design
Background & Challenges
The manufacturer's U.S. plant did not have an established process for producing the component domestically. The existing European system had a complex design and depended on overseas service and replacement parts. Replicating its architecture, even with U.S.-sourced components, would have carried forward unnecessary complexity.
Under the existing model, unplanned downtime could mean waiting for overseas technical assistance, while replacement parts were subject to international lead times. Bringing in PMi2 gave the manufacturer a chance to reassess the design before committing to a direct copy.
Objectives & Scope
The manufacturer needed a U.S.-built automation system that could meet the required production volume, use domestically available parts, and be serviced by a local team. PMi2's scope included system design, engineering, build, and commissioning.
- Replace reliance on offshore equipment with a U.S.-built system
- Match or exceed the original system’s output
- Reduce system complexity and maintenance demands
- Source all components domestically
- Establish a local service relationship
Approach & Execution
PMi2 engineers used the original European design as a starting point. Before making build decisions, they assessed its components and operating sequences for unnecessary complexity. That review led to a simpler final design.
Design Review
PMi2 engineers analyzed the original system to determine which components and sequences could be simplified without compromising output or reliability.
Simplified Architecture
PMi2 redesigned the system with fewer components, a smaller footprint, and easier maintenance using locally available parts.
Domestic Sourcing
PMi2 sourced all components from U.S. suppliers, making replacement parts available without international lead times.
Local Service Partnership
PMi2 became the manufacturer's local service partner, providing domestic access to technical assistance and replacement parts.
Results & Impact
The completed system exceeded the original design’s output while using fewer components and 40% less floor space. It also costs less to build and gives the U.S. plant domestic access to replacement parts and PMi2 service.
Lower capital cost than duplicating the original design
Fewer components and reduced maintenance exposure
100% U.S.-sourced components
Local PMi2 service without reliance on overseas response times
Success Insights
Reviewing the existing system before design began revealed opportunities for simplification that a direct copy would have missed.
A simpler architecture lowered capital cost, floor space requirements, and long-term maintenance exposure.
Domestic sourcing and local service reduced exposure to international parts and service delays.
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