The lithium ion battery global market size was expected to be USD 44.49 billion in 2021 and is projected to reach USD 193.13 billion by 2028.*  Six Sigma is used to improve quality in lithium ion and lithium thermal battery production. We’ll look at applications from Sweden, Denmark, and the USA and finish with a video of how lithium batteries are made for hybrid and electric vehicles.



Applying Six Sigma to Improve the Quality of Lithium-Ion Battery Cell Assembly: Sweden


In a Master’s thesis titled “Six Sigma for quality assurance of Lithium-ion batteries in the cell assembly process: A DMAIC field study at Northvolt” author Mani Mostafaee discusses a framework to control particle contamination in the cell assembly process for lithium-ion batteries.

The thesis includes:

  • Process Map for Cylindrical Battery Assembly
  • Risk Assessments for Cylindrical Battery Assembly Process
    • Machine-Based Risk Levels
    • Beading Machine Risks
    • Winding Machine Risks
  • Measurement Methods and Details
  • Analysis of Particle Stamps
  • Ishikawa Diagram for Technical Cleanliness Issues
  • Particle Contamination Reduction Before and After Cleaning Gloves
  • Final Recommendations

You can read the thesis here.


Six Sigma DMAIC in Lithium-Ion Battery Production: Denmark


In a paper titled “DMAIC in Lithium-Ion-Battery Production” authors Claus Weihs, Oliver Meyer and Sarah Schnackenberg demonstrate the Define, Measure, and Analyze steps for the calendering step in Lithium-Ion-Battery Production.

The paper includes:

  • Calendering Process
  • Measurement Systems Analysis
  • Experimental Design and Analysis

**NOTE ** Clicking on this link will automatically download the paper.


Six Sigma Used to Reduce Product Variability in Lithium Thermal Battery Development: USA-Pennsylvania


In a PowerPoint presentation titled “Thermal Battery Development – Reduced Product Variability Through Six Sigma and Materials Finger-Printing” authors Paul F. Schisselbauer and John Bostwick

discuss a thermal battery development effort where product variability is reduced through the use of Six-Sigma tools, materials characterization or “finger-printing”, and automation.

The presentation includes:

  • Battery Type Performance Comparison
  • Process Definition Using Six Sigma
  • Thermal Battery Description
  • Manufacturing Processes
  • Process and Material Control
  • Materials Characterization
  • Cost Reduction Initiatives

You can view the presentation here.


Manufacturing Lithium Batteries for Hybrid or Electric Vehicles


See how lithium batteries are manufactured in this video from How Its Made.





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