Introduction

Ensuring the highest standards of product quality and safety in rechargeable battery manufacturing requires more than pre-delivery inspections; the underlying root causes of all defects that occur during production must be identified and addressed. To achieve this, manufacturing processes increasingly rely on facility monitoring systems. Prompt detection and response to issues in manufacturing and assembly are essential to reducing and eliminating defects in battery production.

Limitations of Conventional Monitoring Systems

Traditional production monitoring systems face significant limitations that hinder their effectiveness:

Lack of Real-Time Monitoring : Conventional systems typically do not provide real-time surveillance. IP cameras capture footage that is stored in a database for later review. This reactive approach often results in the identification of issues only after a substantial number of defective products have been produced, causing losses and impacting quality control.
Labor-Intensive and Time-Consuming : Manually reviewing recorded footage to identify defects is both time-consuming and labor-intensive. This process not only incurs high labor costs but also carries the risk of missed anomalies, particularly if they are subtle or occur rapidly.

Introducing SAIGE VIMS: An Advanced Solution for Real-Time Monitoring

SAIGE has developed the Video Intelligent Monitoring System (VIMS) to address the shortcomings of traditional monitoring systems. SAIGE VIMS leverages machine learning algorithms to analyze video footage from IP cameras in real-time, detecting and immediately alerting users to any abnormal activities.

Key Features of SAIGE VIMS

Real-Time Detection and Notification : SAIGE VIMS provides instantaneous alerts upon detecting abnormalities, enabling swift corrective actions. Even if immediate intervention is not possible, the system stores footage of the detected anomalies separately for quick and efficient diagnosis.
Enhanced Analysis and Management : The system offers detailed information to facilitate easy analysis of any detected issues, improving overall management efficiency.

Case Study: SAIGE VIMS in a Rechargeable Battery Manufacturing Plant

SAIGE VIMS was deployed at a rechargeable battery manufacturing plant to monitor several critical processes. The plant, equipped with approximately 200 IP cameras, deployed SAIGE VIMS to 25 cameras overseeing key problematic processes. This implementation led to immediate responses to production issues, significantly reducing the number of defective batteries produced and enhancing overall production yield and quality.

(Example) Welding Rod Joining Process: A notable application was in the welding rod joining process. In this stage, welding rods are used to weld tabs and battery cases. A critical issue identified was the slight tilting of welding rods, which could cause significant defects by damaging the jelly roll during the insertion process.

SAIGE VIMS detected the tilting and promptly alerted the operator. The operator could then review the footage and quickly correct the machine, preventing further defects and avoiding potential customer delivery issues and associated losses.

Conclusion

Identifying and addressing the root causes of defects in real-time is vital for improving product quality and reducing production costs. As demonstrated in the case study, without real-time monitoring, defects can proliferate rapidly, leading to increased material consumption and losses.

With SAIGE VIMS, manufacturers can achieve real-time monitoring and immediate anomaly detection, eliminating the need for manual review. SAIGE VIMS allows customers to automate real-time production monitoring and significantly enhance overall operational efficiency.

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