Implementing Quality and Lean Six Sigma in Solid-State Battery Manufacturing

Abstract

The solid-state battery manufacturing industry stands at the cutting edge of energy storage, particularly as demand for electric vehicles (EVs) accelerates. Achieving high standards in both quality and efficiency is essential. One of the major challenges in this process is maintaining strict contamination controls as even minuscule particles or debris can lead to defects that may affect battery quality, safety, and performance. Using Lean Six Sigma methodologies alongside ISO 14644-1 cleanroom standards, this research targets contamination issues with a focus on key performance indicators such as airborne particle concentration and airflow dynamics. Techniques like 5S, root cause analysis, and automated cleaning systems were implemented to systematically reduce contaminants, enhance cleanroom compliance, and increase operational efficiency. Through statistical approaches, including design of experiments and hypothesis testing, this study identified optimal cleaning strategies for different production phases. Quality Engineering tools—such as the 8D problem-solving method, Corrective and Preventive Actions, and Measurement System Analysis (MSA) Gage R&R—were also applied to assess and address contamination sources. The results demonstrated significant reductions in both debris levels and process variability, supporting higher product reliability and cleaner manufacturing processes. This structured approach highlights the potential for data-driven, quality-focused improvements in solid-state battery production, offering valuable insights for advancing EV technology through cleaner, more reliable manufacturing processes.