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Samsung SDI EV Battery
Manufacturing Plan
Edmond Kwok
Chris Suk
SJSU ENGR297G
Overview
• Mission statement
• Demand forecast
• Product information
• Process flow
• Bill of material
• Equipment selection
• Plant layout
• Labor
• Yields and uptime
• Ramp plan
• Cost of goods
• Cost analysis: manual vs full automation assembly
SJSU ENGR297G
Mission Statement
Samsung SDI will build a third battery production line dedicated
to automotive applications to meet increasing EV demands.
Location: Ulsan, South Korea
Capacity: 5 GWh per year
Operation: 24/7/365, 3 shifts
Labor: Semi-automated
Supply capacity by 2020: ~100,000 EV per year
SJSU ENGR297G
SDI supplies batteries for…
BMW i3 – 22 kWh
BMW i8 (HEV) – 7.1 kWh
BMW X5 eDrive (future) – 9.0 kWh
BMW i5 (future?)
Chrysler Fiat 500e – 24 kWh
BMW CEO says they will make 100,000 electric vehicles a year by 2020
SJSU ENGR297G
EV Range
• 3-4 miles range per kWh
• 200 miles range is ideal
SJSU ENGR297G
Demand Forecast
200 𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚
4 𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚 𝑝𝑝𝑝𝑝𝑝𝑝 𝑘𝑘𝑘𝑘𝑘
= 50 kWh
SJSU ENGR297G
Demand Forecast
200 𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚
4 𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚 𝑝𝑝𝑝𝑝𝑝𝑝 𝑘𝑘𝑘𝑘𝑘
= 50 kWh
100,000 EVs x 50 kWh = 5 GWh per year
SJSU ENGR297G
Product
Form factor: Large format prismatic
Cathode: LiNiMnCoO2
Anode: Graphite
Sizes: 28Ah, 40Ah, 60Ah, 64Ah
SJSU ENGR297G
NCM: ~160 Wh/kg
SJSU ENGR297G
Process Flow
SJSU ENGR297G
Mixing Coating
Calendaring Slitting
Electrode Fabrication
Viscosity
Percent
Solids
Loading
Check
Thicknes
s check Assembly
Cathode:
Lithium
Nickel
Manganese
Cobalt
Oxalic Acid
NMP
PVDF
Anode:
Graphite
PVDF
NMP
Cathode:
Aluminum Foil
Anode:
Copper Foil
SJSU ENGR297G
Winding Insertion
Gang
Welding
Tabs
Electrolyte
Fill
Laser
Welding
Enclosure
Degassing
Formation
Assembly
Jelly Roll (9x)
Prismatic Enclosure
Cathode
Anode
Separator
Tab Stock
Cap
SJSU ENGR297G
Formation
Initial
Charge
Full
Discharge
Check
Voltage
Partial
Charge
Sorting & Shipping
Hold for
21 days
Remove Bad Cells
SJSU ENGR297G
Bill of Materials
Samsung SDI Large Format Prismatic Cell BOM
BOM
Level Part name Units Cost per unit Cost per cell Supplier
1 Cover 1 $0.15 $0.22 In-house
2 Pressure Vent 1 $0.15 $0.22 In-house
2 Battery Terminals 2 $0.20 $0.58 In-house
2 Current Collector 2 $0.20 $0.58 In-house
2 Polystyrene insulator 4 TBD TBD TBD
1 Metal prismatic can 1 In-house
1 Jelly roll 9 N/A N/A In-house
2 Al Tabs (2mm width) 9 $0.05 $0.65 Samsung
2 Ni Tabs (2mm width) 9 $0.05 $0.65 Samsung
2 Tape 2 $0.01 $0.02 Samsung
2 Anode 1 N/A N/A
3 Oxalic acid kg $0.65 $0.05 Alibaba
3 PVDF (Indirect) kg N/A N/A Alibaba
3 NMP (Indirect) kg $5.00 $0.60 Alibaba
3 Graphite kg $18.00 $5.21 Samsung
3 Cu Foil kg $10.00 $2.63 Samsung
2 Cathode 1 N/A N/A
3 LiNiCoMnO2 active kg $20.00 $9.85 Samsung
3 Carbon kg $0.60 $0.05 Samsung
3 PVDF kg N/A N/A Alibaba
3 Al Foil kg $5.00 $0.61 Samsung
2 Separator sq m $1.00 $2.89 Polypore
1 Electrolyte kg $40.00 $3.51 Samsung
2 Additives kg TBD TBD Samsung
1 Top insulator 1 $0.02 $0.03
1 Bottom insulator 1 $0.02 $0.03
SJSU ENGR297G
Mixer Selection
LiNiCoMnO2 active: 12,268,034 kg per year
Graphite: 7,202,896 kg per year
Equipment Supplier: Asada
Cathode prep: 4 x 1000 gallon mixers
Anode prep: 2 x 1000 gallon mixers
Cathode mix: 4 x 1000 gallon mixers
Anode mix: 2 x 1000 gallon mixers
12 operators
2 engineers
2 QC
1 supervisors
SJSU ENGR297G
Coater Selection
Equipment Supplier: Hirano
Cathode coater:
7 x 30 meter drying zone
7 x NMP abatement
Anode coater:
10 x 30 meter drying zone
26 operators
2 engineers
2 QC
2 supervisor SJSU ENGR297G
Calender Selection
Equipment Supplier: Hitachi
Cathode:
3 x 1000mm web calender
Anode:
3 x 1000mm web calender
6 operators
2 engineers
2 QC
1 supervisor
SJSU ENGR297G
Slitting
Equipment Supplier: Nishimura
Cathode:
3 x slitter (50m/min)
Anode:
3 x slitter (50m/min)
6 operators
2 engineers
2 QC
1 supervisor
SJSU ENGR297G
Winding
Equipment Supplier: TBD
8 x large format winders
6 operators
2 engineers
2 QC
1 supervisor
SJSU ENGR297G
Dry Room
1 x 30,000 square foot
SJSU ENGR297G
Automated Assembly
Equipment Supplier: Hitachi
3 x full automation line
3 operators
2 engineers
2 QC
1 supervisor
SJSU ENGR297G
Formation
Channels
Capacity: 60A max
Cost: 500$ per channel
# of Channels: 79,621
41 operators
2 engineers
2 QC
3 supervisors
Cell charge/discharge: 20 hours
Extended hold: 21 days
SJSU ENGR297G
Plant Layout
Material
Stores
Finished
Goods
Mixing
Coating
Cathode
Anode
Converting
Dry Room
Cathode Calendaring and Slitting
Anode Calendaring and Slitting
Offices
Assembly
Formation
1” = 30m
339,770 sq ft
557’ x 610’
SJSU ENGR297G
Labor
Average wage – Ulsan, South Korea
Operator: $14.77 per hour
Manufacturing Supervision: $22.24 per hour
Manufacturing Engineer: $31.79 per hour
Overhead: 38%
Direct labor cost: $18,208,516
Indirect labor cost: $11,075,320
SJSU ENGR297G
Yields and Uptime
Capacity: 27 million cells per year
SJSU ENGR297G
Ramp Plan
Production capacity
2016 – 47%
2017 – 53%
2018 – 73%
2019 – 80%
2020 – 100%
SJSU ENGR297G
Ramp Plan
SJSU ENGR297G
Material Costs
SJSU ENGR297G
Capacity: 27 million cells per year
Cost of Goods
SJSU ENGR297G
Capacity: 27 million cells per year
Cost of Goods
BMW i3: 96 cells x $30.62 = ~$3000
SJSU ENGR297G
$1715.60 x 8 = ~$13,725
SJSU ENGR297G
Assembly: Manual vs Automation
Manual assembly
7 assembly lines
$1.75 million capital
49 operators
90% process yield
Automated assembly
3 automated lines
$9 million capital
3 operators
97% process yield
SJSU ENGR297G
Assembly: Manual vs Automation
Manual assembly
7 assembly lines
$1.75 million capital
49 operators
90% process yield
Automated assembly
3 automated lines
$9 million capital
3 operators
97% process yield
SJSU ENGR297G
Assembly: Manual vs Automation
Manual assembly
7 assembly lines
$1.75 million capital
49 operators
90% process yield
Automated assembly
3 automated lines
$9 million capital
3 operators
97% process yield
SJSU ENGR297G
Assembly: Manual vs Automation
Manual assembly
7 assembly lines
$1.75 million capital
49 operators
90% process yield
Automated assembly
3 automated lines
$9 million capital
3 operators
97% process yield
SJSU ENGR297G
Assembly: Manual vs Automation
Manual assembly
7 assembly lines
$1.75 million capital
49 operators
90% process yield
Automated assembly
3 automated lines
$9 million capital
3 operators
97% process yield
$53.5 million per year difference!
SJSU ENGR297G
Thank you!

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Samsung SDI Plant Project

  • 1. Samsung SDI EV Battery Manufacturing Plan Edmond Kwok Chris Suk SJSU ENGR297G
  • 2. Overview • Mission statement • Demand forecast • Product information • Process flow • Bill of material • Equipment selection • Plant layout • Labor • Yields and uptime • Ramp plan • Cost of goods • Cost analysis: manual vs full automation assembly SJSU ENGR297G
  • 3. Mission Statement Samsung SDI will build a third battery production line dedicated to automotive applications to meet increasing EV demands. Location: Ulsan, South Korea Capacity: 5 GWh per year Operation: 24/7/365, 3 shifts Labor: Semi-automated Supply capacity by 2020: ~100,000 EV per year SJSU ENGR297G
  • 4. SDI supplies batteries for… BMW i3 – 22 kWh BMW i8 (HEV) – 7.1 kWh BMW X5 eDrive (future) – 9.0 kWh BMW i5 (future?) Chrysler Fiat 500e – 24 kWh BMW CEO says they will make 100,000 electric vehicles a year by 2020 SJSU ENGR297G
  • 5. EV Range • 3-4 miles range per kWh • 200 miles range is ideal SJSU ENGR297G
  • 6. Demand Forecast 200 𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚 4 𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚 𝑝𝑝𝑝𝑝𝑝𝑝 𝑘𝑘𝑘𝑘𝑘 = 50 kWh SJSU ENGR297G
  • 7. Demand Forecast 200 𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚 4 𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚 𝑝𝑝𝑝𝑝𝑝𝑝 𝑘𝑘𝑘𝑘𝑘 = 50 kWh 100,000 EVs x 50 kWh = 5 GWh per year SJSU ENGR297G
  • 8. Product Form factor: Large format prismatic Cathode: LiNiMnCoO2 Anode: Graphite Sizes: 28Ah, 40Ah, 60Ah, 64Ah SJSU ENGR297G
  • 11. Mixing Coating Calendaring Slitting Electrode Fabrication Viscosity Percent Solids Loading Check Thicknes s check Assembly Cathode: Lithium Nickel Manganese Cobalt Oxalic Acid NMP PVDF Anode: Graphite PVDF NMP Cathode: Aluminum Foil Anode: Copper Foil SJSU ENGR297G
  • 12. Winding Insertion Gang Welding Tabs Electrolyte Fill Laser Welding Enclosure Degassing Formation Assembly Jelly Roll (9x) Prismatic Enclosure Cathode Anode Separator Tab Stock Cap SJSU ENGR297G
  • 14. Bill of Materials Samsung SDI Large Format Prismatic Cell BOM BOM Level Part name Units Cost per unit Cost per cell Supplier 1 Cover 1 $0.15 $0.22 In-house 2 Pressure Vent 1 $0.15 $0.22 In-house 2 Battery Terminals 2 $0.20 $0.58 In-house 2 Current Collector 2 $0.20 $0.58 In-house 2 Polystyrene insulator 4 TBD TBD TBD 1 Metal prismatic can 1 In-house 1 Jelly roll 9 N/A N/A In-house 2 Al Tabs (2mm width) 9 $0.05 $0.65 Samsung 2 Ni Tabs (2mm width) 9 $0.05 $0.65 Samsung 2 Tape 2 $0.01 $0.02 Samsung 2 Anode 1 N/A N/A 3 Oxalic acid kg $0.65 $0.05 Alibaba 3 PVDF (Indirect) kg N/A N/A Alibaba 3 NMP (Indirect) kg $5.00 $0.60 Alibaba 3 Graphite kg $18.00 $5.21 Samsung 3 Cu Foil kg $10.00 $2.63 Samsung 2 Cathode 1 N/A N/A 3 LiNiCoMnO2 active kg $20.00 $9.85 Samsung 3 Carbon kg $0.60 $0.05 Samsung 3 PVDF kg N/A N/A Alibaba 3 Al Foil kg $5.00 $0.61 Samsung 2 Separator sq m $1.00 $2.89 Polypore 1 Electrolyte kg $40.00 $3.51 Samsung 2 Additives kg TBD TBD Samsung 1 Top insulator 1 $0.02 $0.03 1 Bottom insulator 1 $0.02 $0.03 SJSU ENGR297G
  • 15. Mixer Selection LiNiCoMnO2 active: 12,268,034 kg per year Graphite: 7,202,896 kg per year Equipment Supplier: Asada Cathode prep: 4 x 1000 gallon mixers Anode prep: 2 x 1000 gallon mixers Cathode mix: 4 x 1000 gallon mixers Anode mix: 2 x 1000 gallon mixers 12 operators 2 engineers 2 QC 1 supervisors SJSU ENGR297G
  • 16. Coater Selection Equipment Supplier: Hirano Cathode coater: 7 x 30 meter drying zone 7 x NMP abatement Anode coater: 10 x 30 meter drying zone 26 operators 2 engineers 2 QC 2 supervisor SJSU ENGR297G
  • 17. Calender Selection Equipment Supplier: Hitachi Cathode: 3 x 1000mm web calender Anode: 3 x 1000mm web calender 6 operators 2 engineers 2 QC 1 supervisor SJSU ENGR297G
  • 18. Slitting Equipment Supplier: Nishimura Cathode: 3 x slitter (50m/min) Anode: 3 x slitter (50m/min) 6 operators 2 engineers 2 QC 1 supervisor SJSU ENGR297G
  • 19. Winding Equipment Supplier: TBD 8 x large format winders 6 operators 2 engineers 2 QC 1 supervisor SJSU ENGR297G
  • 20. Dry Room 1 x 30,000 square foot SJSU ENGR297G
  • 21. Automated Assembly Equipment Supplier: Hitachi 3 x full automation line 3 operators 2 engineers 2 QC 1 supervisor SJSU ENGR297G
  • 22. Formation Channels Capacity: 60A max Cost: 500$ per channel # of Channels: 79,621 41 operators 2 engineers 2 QC 3 supervisors Cell charge/discharge: 20 hours Extended hold: 21 days SJSU ENGR297G
  • 23. Plant Layout Material Stores Finished Goods Mixing Coating Cathode Anode Converting Dry Room Cathode Calendaring and Slitting Anode Calendaring and Slitting Offices Assembly Formation 1” = 30m 339,770 sq ft 557’ x 610’ SJSU ENGR297G
  • 24. Labor Average wage – Ulsan, South Korea Operator: $14.77 per hour Manufacturing Supervision: $22.24 per hour Manufacturing Engineer: $31.79 per hour Overhead: 38% Direct labor cost: $18,208,516 Indirect labor cost: $11,075,320 SJSU ENGR297G
  • 25. Yields and Uptime Capacity: 27 million cells per year SJSU ENGR297G
  • 26. Ramp Plan Production capacity 2016 – 47% 2017 – 53% 2018 – 73% 2019 – 80% 2020 – 100% SJSU ENGR297G
  • 29. Capacity: 27 million cells per year Cost of Goods SJSU ENGR297G
  • 30. Capacity: 27 million cells per year Cost of Goods BMW i3: 96 cells x $30.62 = ~$3000 SJSU ENGR297G
  • 31. $1715.60 x 8 = ~$13,725 SJSU ENGR297G
  • 32. Assembly: Manual vs Automation Manual assembly 7 assembly lines $1.75 million capital 49 operators 90% process yield Automated assembly 3 automated lines $9 million capital 3 operators 97% process yield SJSU ENGR297G
  • 33. Assembly: Manual vs Automation Manual assembly 7 assembly lines $1.75 million capital 49 operators 90% process yield Automated assembly 3 automated lines $9 million capital 3 operators 97% process yield SJSU ENGR297G
  • 34. Assembly: Manual vs Automation Manual assembly 7 assembly lines $1.75 million capital 49 operators 90% process yield Automated assembly 3 automated lines $9 million capital 3 operators 97% process yield SJSU ENGR297G
  • 35. Assembly: Manual vs Automation Manual assembly 7 assembly lines $1.75 million capital 49 operators 90% process yield Automated assembly 3 automated lines $9 million capital 3 operators 97% process yield SJSU ENGR297G
  • 36. Assembly: Manual vs Automation Manual assembly 7 assembly lines $1.75 million capital 49 operators 90% process yield Automated assembly 3 automated lines $9 million capital 3 operators 97% process yield $53.5 million per year difference! SJSU ENGR297G