Electrochem Capabilities
Agenda
1. Who Is Electrochem?
2. Powering Critical Applications
3. Operational Excellence
4. Looking Forward
5. Electrochem: Partner of Choice
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What We Do
Electrochem is the premium provider of custom battery solutions to niche applications with high energy requirements operating in extreme environments
where the cost of failure is significant.
Electrochem designs and manufactures primary lithium cells and battery packs; secondary battery packs; and battery chargers.
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Our Vision
Enhancing lives worldwide by providing superior power solutions that enable the success and
advancement of our customers’ critical applications.
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A Value Add, Power Solutions Partner
We Are a Power Solutions Company
We understand our customers and their markets, partnering to bring your designs to life.
• Market drivers • Unmet end-user needs • Product materials and design challenges• Organizational structure and product development processes
We Add Value to Your Business
We help our customers build products, that emphasize safety and reliability, for applications where battery failure is not an option.
• Quality focused manufacturing• Technology advancements • Security of supply
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Electrochem Core Competencies
1. Experience- 40+ years experience with critical battery applications- Extensive battery chemistry knowledge and fundamentals, including proprietary electrolytes and a
variety of cathode chemistries
2. Quality & Reliability- Failure is not an option- Multi-discipline product development teams applying DfX principles and other risk mitigation tools- Comprehensive product/process qualifications and validations
3. Technological Innovation- Wide Range Batteries: Low temperature deck check capabilities and improved inventory control- High Temperature Batteries: Pushing temperature limits beyond 200°C
4. Culture of Continuous Improvement- Lean manufacturing systems- Continuous improvement initiatives leveraging Six Sigma methodologies
5. Safety & Compliance- Numerous global certifications and compliance measures (ISO, UL, CE, IATA, DGR, TCC)- Fail-safes incorporated into all battery pack designs ensuring user safety
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Electrochem, an Integer Company
• Integer is one of the worlds largest medical device outsource manufactures, delivering revenues approaching $1.4B annually with numerous locations throughout the world.
• Electrochem operates as an Integer company, part of Integer at the highest level, while maintaining independent leadership, processes, and decision making. Our heritage for superior quality, reliability, and innovation are part of our DNA; deeply rooted from our origins when Wilson Greatbatch invented the battery for the first implantable pacemaker.
• Electrochem is uniquely positioned to benefit from this structure. We have the ability to leverage the extensive resources of Integer when needed, while maintaining the flexibility to operate independently. This allows us to have the stability and influence of a larger company with the focus and agility of a smaller one.
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Our Operations – Raynham, MAFacility: 82,000 sq ft,, expandable to 122,000 sq ft, (owned)Staffing: 260 Associates Current Utilization: 2 Shifts, 5 days x 8 hour shift (>70%)Regulatory: ITAR, DHS, PSM, 21CFR Section 820 Quality System: ISO9001:2008, ISO13485:2012, FDA RegisteredTechnical Capabilities: Primary lithium cell technology, Cathode & Electrolyte technologies, Battery pack assembly techniques, IPC610 soldering, laser welding & marking, glass-to-metal seals, ultrasonic & resistance welding, robotic assy.
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Product Capabilities
• Primary Cells & Battery Packs
• Secondary Battery Packs
• Secondary Battery Chargers
• Complete primary battery production, from cell manufacturing through final pack assembly and testing
• Vast portfolio of technical capabilities, intellectual capital, and industry experience ensuring the ability to meet all project requirements
• Eagle Eye Program: Associate engagement program designed to drive a zero defect safety & quality culture
State-of-the-Art Facility
• Fortified infrastructure (room within a building) and automated event isolation chamber system ensuring operational safety and continuity
• Includes advanced R&D, rapid prototyping, and testing laboratories
• Highly secured and controlled environments for protection of our people and products
• Designed to embrace a Lean Enterprise and Six Sigma approach across all activities
• Business sensible “green” building
Security of Supply
• Business Recovery Plan: In the event of a disaster or catastrophic event, a comprehensive business recovery plan is maintained; critical, redundant equipment is stored offsite for expedited resumption of full production
• Supplier Management Process: Ensures the uninterrupted flow of incoming materials and required services
• Risk Assessments: Regularly conducted to ensure adequate controls are in place and all potential scenarios are evaluated
• Designed-in safety controls and redundant facility infrastructure
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The Leader in Battery Solutions for Critical Applications
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Energy
• Downhole Drilling
• Pipeline Inspection
• Marine Seismic Surveying
Military
• Communications & Surveillance
• Avionics & Sensors
Environmental
• Oceanographic Systems
• Detection & Monitoring
• Industrial/Utility
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Solutions
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Primary Cells
Primary Battery Packs
Secondary Battery Packs
Secondary Battery Chargers
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Cells
Electrochem makes a broad range of sizes and types of cells
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Rate Capabilities Temperature Ranges Typical Capacities
Low RateMemory back-up
Moderate RateDown hole power (current industry
standard)
High RatePipeline inspection, seismic surveying,
oceanographic, aerospace, etc.
< 100°C PIG, military/aerospace, oceanographic, etc.
AA 1.5Ah
C 6.0Ah
D 12Ah
CC15Ah
DD 29Ah
TSD 40Ah
< 150°C Majority of Oil & Gas drilling
< 165°C Oil & Gas drilling
< 180°C Deep Oil & Gas drilling
< 210°C Ultra-deep Oil & Gas drilling
Cell Chemistries
Thionyl Chloride (SOCl2)
• Widely used in downhole market• Excellent performance at high temperatures• Open circuit voltage = 3.67 V
BCX (SOCl2 with BrCl additive)
• Enhanced performance and safety at very low temperatures
• Developed for use on Space Shuttle missions, also used in oceanographic applications
• Open circuit voltage = 3.9 V
Sulfuryl Chloride, or “CSC” (SO2Cl2)
• Highest energy density• Best performance is obtained at moderate
temperatures, but also used in some high temperature downhole applications
• Open circuit voltage = 3.93 V
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Cell Construction
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Low Rate
• Bobbin design: simple and rugged
• Small cell sizes, memory back-up and similar applications
Moderate Rate – Dual Anode
• Modified bobbin design with second layer of anode: simple & rugged, but higher rate capability
• The workhorse of Electrochem’s downhole offerings: in widespread use for more than 25 years
High Rate – Spiral
• Higher surface area electrodes
• Ruggedized designs (“MWD,” WR) can withstand downhole shock & vibration
• High rate cells include an inaccessible external fuse
Custom Pack Examples
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Energy – MWD/LWD Operations Energy – Pipeline Inspection
Environmental – Subsea Surveillance Military – Primary Power
Quality Systems / CI Focus
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Plan
Quality System Controls
Do
NPI / Production
Check
Monitoring
Act
Improvement
Quality System Controls• Change Management• Risk Management• Validation• Spec Concurrence• Product Development Process• Equipment Management• Process Control• Training
Monitoring• Nonconformance Management• Gate Calls• Customer Feedback and Complaints• Production Data and Trending• Equipment Performance• Operational Efficiency• Internal Audits
Improvement• Corrective Action• Kepner-Tregoe Projects• Quick Fixes• Eagle Eye Program• Kaizen
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Safety-Based Culture
Behavioral Based Safety Program
• Observation based program promoting proactive safe behavior before incidents, or near misses, occur.
• Associates are trained to observe peers and provide immediate, effective, safety feedback.• Observations are collected and shared anonymously with all associates to promote
continuous improvement.• The goal is for safe behavior to become “second nature” for all associates.
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The Eagle Eye Program
• An associate driven feedback process focusing on facility quality & safety improvements.
• Any associate can submit an Eagle Eye suggestion.• Associates who submit Eagle Eye suggestions have the opportunity to
select a small award for their contribution to improve quality and safety.• Each quarter, a group of associates is presented with the “Soaring
Eagle” award for the most active participation that positively impacted quality and safety.
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Regulatory Compliance
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Monitor compliance to all applicable regulations and industry standards• STP update subscriber• ICAO, IATA, UN, DOT, FAA• UL, IEC• OSHA• RoHS, REACH, WEEE• Conflict Minerals
Battery industry leading SME• NEMA & PRBA battery council member• Industry representative to government agencies and dangerous
goods panels• Educate regulators• Provide input into proposed regulations
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Lean Enterprise
Lean Center of Excellence (COE)• Business and operations process optimization driven by Hoshin plan
Synchronization • Drive standard processes and best practices across the enterprise
(lean, supply chain, finance, etc)
Supplier Development• Work directly with supply base to reduce costs, reduce lead time,
improve delivery/performance
Greatbatch Production System (GPS)• Comprehensive production system deployment
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Product Lifecycle Management
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Conceive
Plan / Design / Develop
Service
Realize
Verify
Dedicated project manager
facilitates the assigned cross-
functional team through the
design and development steps
Qualifications and
Validations completed &
documented
Production transfer and
scale-up
Technical Support, Global Site Support,
Sustaining Engineering Activities
including material obsolescence & EOL
Management
Project requirements and
specifications defined
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Custom Pack Development Process
NPI Development Cycle: 6 – 18 Months
Build To Print Development Cycle: 4 – 6 Months
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PlanningDesign Inputs
Design Outputs
Verification &
Validation
Scale Up & Transfer
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Portfolio Investments
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Wide Range Technology
• Simplifies inventory controls: One battery can support multiple temperature ranges.
• Improves efficiency: Reduced need for “trip outs” as temperatures change downhole .
• Improves safety & reliability: Allows for safe testing of downhole tools at surface temperatures, before they go downhole.
High Temperature Technology
• Improves data quality: Allows for the use of battery power at temperatures above 200C, removing the signal noise created by traditional power sources.
• Added confidence: High Temperature batteries enable the continuous backup of data if the drill ever needs to stop.
Under Voltage Protection Circuit
• Prevents Over Discharge: Disconnects load when voltage drops below an acceptable limit, reducing the chance of a costly, possibly dangerous, cell vent situation.
• Prevents Voltage Reversal: Eliminates the risk of a cell being driven into voltage reversal from the other cells connected in series, further reducing the possibility of a cell vent.
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Electrochem Delivers
1. Security of Supply• Robust systems to proactively assess, mitigate, and control risk and ensure an
uninterrupted supply of products to customers.
2. Complete Customer Support• Fast and effective customer support including dedicated consult and design teams with
years of industry experience.
3. Unmatched Performance• Superior performance in terms of reusability, discharge rate, and low temperature
operation.
4. A Trusted Partner• As a primary supplier to top companies across numerous industries, we maintain strict
confidentiality to protect our customers.
5. Industry Leading Quality & Reliability• Provider of the safest, highest quality, battery solutions available in the markets we serve.
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