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Samsung SDI Plant Project

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Samsung SDI Plant Project

  1. 1. Samsung SDI EV Battery Manufacturing Plan Edmond Kwok Chris Suk SJSU ENGR297G
  2. 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. 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. 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. 5. EV Range • 3-4 miles range per kWh • 200 miles range is ideal SJSU ENGR297G
  6. 6. Demand Forecast 200 𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚 4 𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚 𝑝𝑝𝑝𝑝𝑝𝑝 𝑘𝑘𝑘𝑘𝑘 = 50 kWh SJSU ENGR297G
  7. 7. Demand Forecast 200 𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚 4 𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚 𝑝𝑝𝑝𝑝𝑝𝑝 𝑘𝑘𝑘𝑘𝑘 = 50 kWh 100,000 EVs x 50 kWh = 5 GWh per year SJSU ENGR297G
  8. 8. Product Form factor: Large format prismatic Cathode: LiNiMnCoO2 Anode: Graphite Sizes: 28Ah, 40Ah, 60Ah, 64Ah SJSU ENGR297G
  9. 9. NCM: ~160 Wh/kg SJSU ENGR297G
  10. 10. Process Flow SJSU ENGR297G
  11. 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. 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
  13. 13. Formation Initial Charge Full Discharge Check Voltage Partial Charge Sorting & Shipping Hold for 21 days Remove Bad Cells SJSU ENGR297G
  14. 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 $0.03 SJSU ENGR297G
  15. 15. Mixer Selection LiNiCoMnO2 active: 12,268,034 kg per year Graphite: 7,202,896 kg per year Equipment Supplier: Asada Cathode prep: 4 x 1000 gallon mixers Anode prep: 2 x 1000 gallon mixers Cathode mix: 4 x 1000 gallon mixers Anode mix: 2 x 1000 gallon mixers 12 operators 2 engineers 2 QC 1 supervisors SJSU ENGR297G
  16. 16. Coater Selection Equipment Supplier: Hirano Cathode coater: 7 x 30 meter drying zone 7 x NMP abatement Anode coater: 10 x 30 meter drying zone 26 operators 2 engineers 2 QC 2 supervisor SJSU ENGR297G
  17. 17. Calender Selection Equipment Supplier: Hitachi Cathode: 3 x 1000mm web calender Anode: 3 x 1000mm web calender 6 operators 2 engineers 2 QC 1 supervisor SJSU ENGR297G
  18. 18. Slitting Equipment Supplier: Nishimura Cathode: 3 x slitter (50m/min) Anode: 3 x slitter (50m/min) 6 operators 2 engineers 2 QC 1 supervisor SJSU ENGR297G
  19. 19. Winding Equipment Supplier: TBD 8 x large format winders 6 operators 2 engineers 2 QC 1 supervisor SJSU ENGR297G
  20. 20. Dry Room 1 x 30,000 square foot SJSU ENGR297G
  21. 21. Automated Assembly Equipment Supplier: Hitachi 3 x full automation line 3 operators 2 engineers 2 QC 1 supervisor SJSU ENGR297G
  22. 22. Formation Channels Capacity: 60A max Cost: 500$ 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. 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. 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. 25. Yields and Uptime Capacity: 27 million cells per year SJSU ENGR297G
  26. 26. Ramp Plan Production capacity 2016 – 47% 2017 – 53% 2018 – 73% 2019 – 80% 2020 – 100% SJSU ENGR297G
  27. 27. Ramp Plan SJSU ENGR297G
  28. 28. Material Costs SJSU ENGR297G
  29. 29. Capacity: 27 million cells per year Cost of Goods SJSU ENGR297G
  30. 30. Capacity: 27 million cells per year Cost of Goods BMW i3: 96 cells x $30.62 = ~$3000 SJSU ENGR297G
  31. 31. $1715.60 x 8 = ~$13,725 SJSU ENGR297G
  32. 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. 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. 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. 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. 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
  37. 37. Thank you!

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