At the 2024 Maintenance Fair, Plantvision recorded an episode of our podcast Beyond Tomorrow on the theme "Production challenges in battery manufacturing", together with Jon Bokrantz, Assistant Professor at Chalmers University of Technology. Jon also leads the research project "Matter at Scale - Maintenance of Battery Production at Industrial Scale". He is actively working on developing future maintenance strategies for battery factories and emphasizes the importance of Sweden not just keeping up - but taking a leading position.
"We need something to hold on to, something to drive us. No one remembers a coward, so we just have to be the best. Sweden has always lived on being small but really sharp. That's what we need to be when it comes to batteries," says Bokrantz.
A unique mix of production processes
Battery production is different from many other industries because it combines several different manufacturing methods. In a single factory, there are processes reminiscent of the chemical industry, pulp and paper manufacturing, medical device production and the automotive industry.
"In cellular manufacturing, you have discrete and continuous manufacturing, one-off production and batch flows - all in the same place. It's like maintaining several different factories at the same time," Bokrantz explains.
This means that the maintenance organization needs expertise in several areas and that maintenance strategies need to be adapted to the specific parts of the production chain. For example, the production of the active material in battery cells is similar to the chemical industry, while the subsequent handling of electrodes and separators is similar to the paper industry with large rolls and rolling processes. When the batteries are then assembled and mounted, it becomes more like discrete manufacturing in the automotive industry.
"It's a mix of different industries coming together under one roof, which means we need to bring in knowledge from multiple sources to build an effective maintenance strategy," says Bokrantz.
Digitalization - huge opportunities but also challenges
As most battery factories are greenfield facilities, i.e. built from scratch, their equipment and machinery are already digitally connected. This means that it is technically possible to monitor and analyze virtually every part of the production process in real time.
"The possibilities are enormous. Everything can be digitized from day one. But going from connectivity to actually using data for decisions requires much more - both technically and organizationally," says Bokrantz.
But having software and hardware on Location is just the beginning. For digitalization to bring real benefits, tools, work processes and organization need to be adapted, so that data actually leads to informed decisions. New factories often lack established routines, which creates a double challenge - while building up production, you also need to create a functioning maintenance strategy from scratch.
"Many people look at new factories and think: 'What a dream to start from scratch with all the technology on Location! But at the same time, the experience-based structure and routines that older factories have built up over decades are missing. It's a balancing act to take advantage of the digital opportunities without losing structure," says Bokrantz.
Lessons from other industries
The battery industry is still in its infancy and can benefit from the experience of other sectors to improve maintenance efficiency. By studying industries with similar production conditions, battery factories can quickly adapt proven maintenance strategies.
"If part of the plant is similar to the chemical industry, then we should maintain that part as a chemical plant. If we have a process similar to the paper industry, then we have to use those maintenance strategies there. It's about taking the best from different industry segments," says Bokrantz.
This approach is already being used by companies like Tesla, whose battery production is inspired by production techniques from the food industry. For example, they have studied how breweries handle large volumes of bottles in continuous flows and applied similar methods to battery production.
A call to suppliers and maintenance specialists
Swedish industry has long experience of manufacturing and maintenance in a range of sectors. Now it is time to apply this knowledge to the battery industry. Bokrantz urges Swedish maintenance suppliers to take an interest in the industry and identify what solutions can be used in battery production.
"The battery industry is hugely important for Sweden and Europe. We have every reason to be involved in shaping it - but this requires more players to get involved and contribute their expertise," he says.
He also highlights the business opportunities for maintenance providers. Many of the maintenance strategies and services used in other industries can be directly applicable in battery production, but require adaptation to the unique processes and high production speed.
"There are plenty of suppliers and technologies that we could use in the battery industry. But it is important that companies dare to take the step and adapt their services to this rapidly growing industry," says Bokrantz.
Conclusion: A unique window for Swedish industry
Battery production is an industry of the future where maintenance strategies play a crucial role in efficiency, productivity and competitiveness. Sweden has a unique opportunity to position itself at the forefront - but this requires companies, researchers and maintenance specialists to collaborate and share their expertise.
The question is: Will Swedish industrial companies and maintenance suppliers seize this opportunity, or do we risk being left behind as other countries take the lead?
