How Surrette Batteries Unlocked Efficiency Through Our Manufacturing Consulting Services
INDUSTRY:
Battery Manufacturing
TYPE OF WORK:
Conceptual design, design validation, analysis, and design for manufacture (DFM)
Our manufacturing consulting services enhance efficiency with advanced data analytics, supply chain optimization, and quality processes. We focus on digitization, lean production, risk management, and sustainability, ensuring regulatory compliance and consistent product quality across various industries.
John Hauser, Discipline Lead, Automation & Robotics
Enginuity
About the Client
Surrette Battery Co.
For almost 90 years, Surrette Battery Company has been producing a wide range of Rolls-branded premium deep cycle batteries for use in renewable energy, marine, motive power, and railroad applications. Surrette Battery Co. is a third-generation family-run business, known worldwide for their high-quality products.
Surrette Battery Co. emphasizes sustainable operations and advanced manufacturing technologies, producing batteries for alternative energy applications in Canada and beyond.
Understanding the Problem
The Challenge
Surrette Battery Co. met the challenge of balancing the need for increased production and operational rising costs head on, all while maintaining high employee satisfaction and reducing manufacturing costs and waste. They sought to enhance operational efficiency and quality processes without compromising product standards. Identifying and eliminating inefficiencies in their manufacturing processes was crucial.
We were tasked to perform a comprehensive process discovery to pinpoint areas of improvement and provide actionable insights for optimizing production workflows, ensuring sustainable operations, and improved productivity.
Step 01: Waterbath Charging Station
A frontline perspective of Surrette's waterbath charging station and process.
Step 02: Battery Casting Department
Surrette's casting department during regular production
Step 03: Production Cell
Front view of a Surrette production cell on one of their battery production lines
Step 04: SCADA Implementation
Display screen of the newly implemented Surrette waterbath monitoring SCADA system
Step 05: Surrette Plant
Surrette representatives discussing battery production line
Solving the Challenge
The Solution
Enginuity applied its expertise to address Surrette Battery Co.’s challenges. Through a comprehensive process discovery, Enginuity identified key inefficiencies in the manufacturing processes, particularly in the waterbath process.
The team implemented advanced factory automation solutions and lean manufacturing practices to streamline operations, focusing on enhancing operational efficiency and quality control. Our approach included on-site visits to gather detailed information on existing processes and equipment, followed by extensive production workflow analysis.
We developed and presented ROI projections for each identified improvement area, highlighting the potential benefits of reduced idle time and optimized cooling systems.
Summarizing the Outcome
The Conclusion
Enginuity’s manufacturing consulting services significantly helped Surrette Battery Co. improve their manufacturing processes. By addressing inefficiencies and implementing advanced solutions, Surrette Battery Co. is now equipped to meet industry demands with enhanced operational efficiency and product quality.
Our solutions have established a foundation for ongoing innovation and excellence at Surrette Battery Co., reducing inefficiencies and boosting productivity. This has solidified their position as a leader in the battery manufacturing industry.
Key Takeaways
Manufacturing Consulting
Optimized Surrette Battery Co.’s processes, enhancing efficiency and product quality.
Process Improvements
Addressed inefficiencies, leading to increased productivity and better operational outcomes.
Risk management
Ensured operational risks were assessed and mitigated, supporting sustainable growth
Applying Manufacturing Consulting Expertise to Broader Markets
The success of the Surrette Battery Co. project showcases our proficiency in delivering advanced manufacturing, process, and risk consulting services that can be applied in various sectors. Our team specializes in integrating factory automation solutions and advanced manufacturing technologies seamlessly within your existing infrastructure.
The insights gained can be applied to develop advanced solutions for:
Food and Beverage Industry: Enhance quality control, ensure compliance with safety standards, and optimize production processes with real-time data on ingredients and contaminants.
Pharmaceutical Industry: Improve drug formulation, quality assurance, and regulatory compliance by leveraging precise chemical composition measurement, streamlining drug development and production.
Agriculture and Horticulture: Monitor soil health, nutrient levels, and plant conditions in real-time, leading to better crop management, higher yields, and more efficient resource use.
Environmental Monitoring: Detect pollutants, track environmental changes, and ensure compliance with environmental regulations by extending our expertise to monitor air and water quality.
Cosmetic Industry: Ensure the safety and efficacy of ingredients, optimize formulations, and maintain consistent product quality with detailed chemical profiling.
With our decades of experience across these sectors, we help clients achieve significant improvements in efficiency, quality, and productivity, driving sustainable growth and success.
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