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Our Manufacturing Capabilities

Our Expertise in Battery Pack Manufacturing

When manufacturing custom battery packs, we aim to produce high-quality, world-class battery packs with maximum efficiency. To achieve this goal, we integrate lean manufacturing with consideration to each aspect of the 6M principle: Machine, Man, Materials, Method, Measure and Mother Nature. Sticking to the lean manufacturing principles ensures that every product we deliver meets the highest quality standards through an efficient production process. We’ve structured our entire operation around these critical pillars, optimising each to maintain world-class production standards. By integrating lean manufacturing principles into our production process, we have extensive capacity across 13 available production lines within our 60,000-square-foot manufacturing space.

EV Flex machine for laser welding battery cells in battery pack manufacturing

Machine

We guarantee precision and consistency when producing every battery pack by prioritising cutting-edge machinery. Using our state-of-the-art programmable welder, we can measure the accuracy of every weld to ensure that it meets the precise guidelines set by an OEM. Our ERP (Enterprise Resource Planning) system allows quick corrective adjustments to maintain optimal performance and production flow. To fully maximise our machine’s outputs, we utilise lean manufacturing practices; this efficiency helps us deliver high-volume demands efficiently.

ABT Quality and Production team

Man

To ensure the efficiency of our manpower, we focus on training all of our operators to manufacture battery packs safely, precisely, and consistently.
All of our operators participate in our two-week training course designed to teach them the advanced techniques needed to be an efficient operator and produce high-quality battery packs. The course is designed with scalability in mind and operators are trained across many production processes to allow seamless integration into any part of the production line required to meet demand. This training course enables our workforce to achieve high quality and consistent output resulting in our low defect rate of just 0.04%.

Warehouse of battery supply chain

Materials

We rely on a network of tier-one suppliers to exclusively source our components for manufacturing high-quality battery packs. Upon arrival, materials undergo PPAP (Production Part Approval Process), with parts being visually and dimensionally inspected to ensure materials are to specification. Using batch numbering and a First In, First Out (FIFO) approach, we know which components have gone into each pack we produce. Our ERP system allows for the traceability of every batch used in manufacturing, enabling continuous evaluation to improve our battery packs and ensure that only the best components will be used in every project. Our global network of tier-1 suppliers ensures we are always able to get materials delivered, protecting us against geopolitical situations and environmental factors that could affect supply.

Two female production line employees are providing end-of-line testing of battery packs.

Method

Using our 40 years of battery pack manufacturing experience, we have created a system of processes that effectively ensures we consistently deliver world-class battery packs. To guarantee efficiency, we implement a lean manufacturing ideology at every stage. A crucial part of our manufacturing method is our defect-logging system which allows for quick identification and resolution of issues, ensuring any problem is never long-lasting; in turn, this supports high quality product output and production efficiency. Through decades of optimisation, we have developed a methodology that leads to a very low defect rate of 0.04%.

Do you have a project that needs a custom battery pack?