To: Rich Wolf who wrote (8094 ) 2/9/1999 12:13:00 PM From: Rich Wolf Read Replies (1) | Respond to of 27311
Addendum re: production rates. Lev stated that currently they're running the large battery cell line at 4 cells/minute, and the small cell line at 25 cells/minute. He said the former rate would be incrementally sped up once they get to production, as the max rated capacity is higher. We asked if he runs it every day and he said no. There's clearly potential for waste at startup, so you want to run it continuously once you get it running at speed. After the cells are configured, they are inserted into foil packages which contain an 'extension,' the electrolyte injected, then the cell is charged (or 'brought to life,' as Lev said). This results in an out-gassing, which is trapped in a 'blister' in the foil extension, which can then be clipped off. After a few days for out-gassing, the cells are laid in trays and put into quarantine chambers for 30 days. My only concerns, as I consider how they will commence bringing the entire production into 'balance' (term Lev used, common in production facilities: means input rates equal output rates at each stage), relates to the packaging and quarantine facilities. The cellphone batteries are packaged (as described above) in a fully-automated fashion, but the laptop cells are inserted into the foil by hand. (There was a long chamber, with gloved access for 6-8 workers (I think) to perform this step.) This could be a production bottleneck, although it is so low-tech as to be easily remedied. Lev did tell us afterwards that they're in the process of duplicating the automated packaging of the small cells for the large cells (new equipment coming in), but that that would not prevent him from accepting a P.O. at this point. The quarantine facility may also need expanding as they go to multiple shifts per day. It'll be fun to watch this facility expand. Lev said he is redirecting more effort to increasing production of laptop cells, as currently they have few potential competitors (due to the difficulty in making lithium-cobalt work safely in such large packages). We may find that higher profit margins can easily be maintained here, and for some time to come. The liquid electrolyte li-ion battery makers can't cut production costs below what they are now, and even if they were to dump, Lev indicated he has a lot of wiggle room to still maintain a profit margin, if he wanted to match them. But he didn't expect he'd have to, since his product has many advantages, both in terms of safety and form factor.