electric vehicle, battery manufacturers & suppliers
Expert Problem Solving
Done for you, or with you.
Trusted by automotive brands
Are your electric vehicle or battery systems facing unexpected setbacks? Do production issues or defects in battery cells, packs, or systems lead to costly delays or safety risks? We understand how complex battery systems can be, and we’re here to help—without requiring you to spend valuable time educating us.
Here’s how we’re uniquely equipped to assist you:
• In-depth knowledge of battery systems
We understand battery systems from inside the cell to the final pack, including Battery Management Systems (BMS) and Thermal Management Systems (TMS). Whether you’re working with Hybrid Electric Vehicles (HEVs), Plug-in Hybrid Electric Vehicles (PHEVs), Battery Electric Vehicles (BEVs), or Energy Storage Systems (ESS), we combine our subject matter expertise with proven problem-solving methodologies to quickly get to the root of the issue.
• Immediate solutions from problem-solving experts
Our experienced team brings not only expertise in battery technology but also a track record of solving complex problems for some of the biggest names in the industry. We’ve successfully worked with companies like yours, helping them address critical issues and develop long-term solutions. Our approach identifies root causes even when evidence is limited, such as in cases where failures have led to fires or other catastrophic outcomes.
• Comprehensive training for self-sufficiency
We also offer Red X® training to develop your team’s problem-solving capabilities. Your engineers and quality professionals will learn to identify and eliminate root causes with precision—without having to rely on outside help. Our training empowers your team to keep production running smoothly and avoid recurring issues.
Shainin is your trusted partner in the electric and hybrid vehicle industry. With deep knowledge of battery systems and 75 years of proven problem-solving experience, we help you solve today’s challenges and prevent tomorrow’s.
Contact us today to learn how we can help you solve complex battery problems and optimize your production line.
Case Study: Solving Walk-Home Events for Hybrid Vehicle Launch
Challenge:
A leading automotive OEM faced a critical issue during the launch of a new hybrid vehicle, with unexpected “walk-home” events caused by battery pack isolation loss, triggering the P0AA6 code. The problem was intermittent, making it difficult to replicate and diagnose, threatening customer satisfaction and the vehicle’s launch success.
Solution:
The OEM partnered with Shainin, who analyzed field data and discovered the failures followed an infant mortality pattern, indicating a production issue. The team focused on five automated welding machines and identified a misalignment during welding as the root cause, which affected battery cell positioning.
Results:
• Corrective Action: Adjusted the welding process to ensure proper cell alignment.
• Eliminated Events: Walk-home events were immediately eliminated, restoring vehicle reliability.
• Successful Launch: Resolved the issue before widespread customer impact, safeguarding the vehicle’s reputation.
Outcome:
With Shainin’s expertise, the OEM successfully launched the hybrid vehicle, maintaining customer trust and avoiding negative publicity.
Innovative structure & refined simplicity that yield speed to resolution
Let our team of dedicated problem solvers help resolve your most impactful issues. Contact us today to team up!
Case Study: Solving Battery Pack Leaks – $90K Annual Savings
Challenge:
An automotive supplier struggled with persistent battery pack leaks during testing, traced to components from a single supplier. Despite meeting specifications, a 7020% leakage rate led to high rework and scrap costs, threatening production efficiency.
Solution:
Using the Shainin Red X Methodology, the team analyzed test data and pinpointed the leaks to a specific area. A deeper investigation revealed that a dimension on the non-sealing surface, though within specifications, was not adequately controlled. The team implemented dimensional control to correct the issue.
Results:
• Eliminated Leaks: The leakage rate dropped from 7020% to zero.
• Cost Savings: The company saved $90,000 annually in parts costs alone, plus reduced rework and scrap expenses.
Outcome:
With Shainin’s guidance, the supplier resolved a complex issue, improving product quality and reducing costs. This success story demonstrates the power of targeted problem-solving techniques in manufacturing.
Case Study: Reducing Battery Pack Leak Failures – $1.6M Annual Savings
Challenge:
A Tier One automotive supplier faced escalating costs due to persistent battery pack leak failures during assembly testing. The issue, which had climbed into their top 5 failures, required extensive rework and scrap, totaling over $500,000 in four months. The sporadic nature of the failures made it difficult to pinpoint the root cause, creating an urgent need for a reliable solution.
Solution:
The supplier partnered with Shainin and used the FACTUAL framework to identify patterns in the failure data. This targeted approach revealed that the root cause was a supplier-related issue. Using the 5-penny test, Shainin confirmed the root cause, providing clear evidence for corrective actions.
Results:
• Supplier Corrective Action: Process improvements were implemented, addressing the root cause.
• Eliminated Rejects: Leak failures were completely eliminated.
• Cost Avoidance: Annual savings of $1.6M in rework and scrap costs.
Outcome:
Shainin’s methodology enabled the supplier to resolve the issue efficiently, improving battery pack reliability and achieving significant cost savings, demonstrating the value of structured problem-solving.
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