Advanced Energy & Battery Manufacturing
MES for battery cell, module, and pack manufacturing
Cell-to-pack genealogy that survives a field recall, formation-line OEE, electrode-coating and OCV/ACIR SPC with Cp/Cpk, and safety-critical torque-plus-angle fastening — all captured at the point of work, on machine signals you already have.
When one cell lot is suspect, you need every affected pack — in seconds, not weeks.
A battery field action is a genealogy problem before it is anything else. A defective electrode batch or a single drifting formation channel can touch tens of thousands of cells, and each cell rolls up through a module into a pack that ships in a specific vehicle or energy-storage rack. Qontiv captures the cell → module → pack ancestry at the point of work, so the recall-scope query returns every affected serial — forward and backward — instead of a forensic reconstruction across coating, formation, and assembly spreadsheets.
Battery plants run continuous coating and formation upstream and discrete module/pack assembly downstream. Most MES products are built for one or the other. Qontiv models both in a single genealogy graph: lot-tracked electrode and electrolyte feeding serial-tracked cells, cells nested into modules, modules torqued into packs — with the SPC, OEE, and fastening evidence attached to the same records the recall query walks.
Built for the battery production chain
Cell → module → pack genealogy & field-recall traceability
One genealogy graph spans the whole chain: lot-tracked electrode coating and electrolyte, serial-tracked cells, modules built from those cells, and packs built from those modules. A cell defect traces forward to every affected module and pack — and a suspect electrode lot traces forward to every cell it ever produced. The recall-scope query returns the complete affected population in seconds. Genealogy is recorded as work happens, never reconstructed after a field action is already open.
- • IEC 62619 — traceability for industrial secondary lithium cells and batteries
- • EU Battery Regulation 2023/1542 — battery passport & component-level traceability
Cell-formation OEE
Formation and aging are the bottleneck and the cost center of a cell line — channels are expensive, cycles are long, and idle capacity is invisible without instrumentation. Qontiv calculates Availability, Performance, and Quality per formation channel and per line directly from machine signals, surfaces the Six Big Losses, and breaks down channel utilization shift by shift. Supervisors see live formation OEE on the floor; managers see the trend without anyone keying a log.
- • Per-channel and per-line Availability / Performance / Quality from real signals
- • Six Big Losses breakdown with reason codes captured at the event
Electrode-coating, bond-gap, OCV & ACIR SPC with Cp/Cpk
Statistical process control on the parameters that decide cell quality: electrode coating weight and thickness, wire-bond gap on module interconnects, open-circuit voltage (OCV), and AC internal resistance (ACIR). Control charts with Western Electric rule detection and Cp/Cpk capability indices catch process drift before it becomes scrapped cells — and every measurement is tied to the serial it came from, so an out-of-control point is one click from its genealogy.
- • Cp/Cpk capability on coating weight/thickness, bond gap, OCV, and ACIR
- • Western Electric rule detection with measurement bound to cell serial
Safety-critical fastening — torque + angle traceability
Module-to-pack and busbar fastening is a safety-critical joint: a loose or over-torqued fastener on a high-voltage interconnect is a thermal-runaway risk. Qontiv captures the torque-and-angle result for every safety-critical fastening operation, ties it to the pack serial and the tool that performed it, and ships electronic work instructions that won't let an operator advance past a NOK rundown. The pack genealogy carries the fastening evidence alongside the cell and module records.
- • Per-fastener torque + angle bound to pack serial and tool identity
- • EWI gating — a NOK rundown blocks the step; rework is recorded, not silent
Native machine connectivity — OPC-UA, MQTT / Sparkplug B, Open Protocol
Battery lines mix coaters, calenders, formation cyclers, laser welders, and DC nutrunners from many vendors. Qontiv's edge gateway speaks OPC-UA and MQTT with Sparkplug B natively, reads safety-critical tightening results over Atlas Copco Open Protocol, and publishes into a Unified Namespace so your plant has one consistent, self-describing data fabric instead of point-to-point integrations. First machine online in under two hours — no middleware project.
- • OPC-UA and MQTT / Sparkplug B — native, not via a connector add-on
- • Atlas Copco Open Protocol for torque/angle tightening results
- • Unified Namespace publishing — one self-describing plant data fabric
What this is — and what it isn't
Qontiv is designed for compatibility with the records, traceability, and controls that IEC 62619, UL 9540, and ISO 9001 assessors look for — and with IATF 16949 where your OEM requires it for EV-drivetrain and traction-battery programs. Qontiv itself is not certified to any of these standards; the certification belongs to your organization. Your certification body audits your management system; Qontiv supplies the evidence.
When the recall comes, will you have the genealogy?
Cell-to-pack traceability, formation OEE, and OCV/ACIR SPC — designed for IEC 62619 and UL 9540.