1. Samsung SDI EV Battery
Manufacturing Plan
Edmond Kwok
Chris Suk
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2. Overview
• Mission statement
• Demand forecast
• Product information
• Process flow
• Bill of material
• Equipment selection
• Plant layout
• Labor
• Yields and uptime
• Ramp plan
• Cost of goods
• Cost analysis: manual vs full automation assembly
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3. Mission Statement
Samsung SDI will build a third battery production line dedicated
to automotive applications to meet increasing EV demands.
Location: Ulsan, South Korea
Capacity: 5 GWh per year
Operation: 24/7/365, 3 shifts
Labor: Semi-automated
Supply capacity by 2020: ~100,000 EV per year
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4. SDI supplies batteries for…
BMW i3 – 22 kWh
BMW i8 (HEV) – 7.1 kWh
BMW X5 eDrive (future) – 9.0 kWh
BMW i5 (future?)
Chrysler Fiat 500e – 24 kWh
BMW CEO says they will make 100,000 electric vehicles a year by 2020
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5. EV Range
• 3-4 miles range per kWh
• 200 miles range is ideal
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6. Demand Forecast
200 𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚
4 𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚 𝑝𝑝𝑝𝑝𝑝𝑝 𝑘𝑘𝑘𝑘𝑘
= 50 kWh
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7. Demand Forecast
200 𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚
4 𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚 𝑝𝑝𝑝𝑝𝑝𝑝 𝑘𝑘𝑘𝑘𝑘
= 50 kWh
100,000 EVs x 50 kWh = 5 GWh per year
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8. Product
Form factor: Large format prismatic
Cathode: LiNiMnCoO2
Anode: Graphite
Sizes: 28Ah, 40Ah, 60Ah, 64Ah
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9. NCM: ~160 Wh/kg
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10. Process Flow
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11. Mixing Coating
Calendaring Slitting
Electrode Fabrication
Viscosity
Percent
Solids
Loading
Check
Thicknes
s check Assembly
Cathode:
Lithium
Nickel
Manganese
Cobalt
Oxalic Acid
NMP
PVDF
Anode:
Graphite
PVDF
NMP
Cathode:
Aluminum Foil
Anode:
Copper Foil
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12. Winding Insertion
Gang
Welding
Tabs
Electrolyte
Fill
Laser
Welding
Enclosure
Degassing
Formation
Assembly
Jelly Roll (9x)
Prismatic Enclosure
Cathode
Anode
Separator
Tab Stock
Cap
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13. Formation
Initial
Charge
Full
Discharge
Check
Voltage
Partial
Charge
Sorting & Shipping
Hold for
21 days
Remove Bad Cells
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14. Bill of Materials
Samsung SDI Large Format Prismatic Cell BOM
BOM
Level Part name Units Cost per unit Cost per cell Supplier
1 Cover 1 $0.15 $0.22 In-house
2 Pressure Vent 1 $0.15 $0.22 In-house
2 Battery Terminals 2 $0.20 $0.58 In-house
2 Current Collector 2 $0.20 $0.58 In-house
2 Polystyrene insulator 4 TBD TBD TBD
1 Metal prismatic can 1 In-house
1 Jelly roll 9 N/A N/A In-house
2 Al Tabs (2mm width) 9 $0.05 $0.65 Samsung
2 Ni Tabs (2mm width) 9 $0.05 $0.65 Samsung
2 Tape 2 $0.01 $0.02 Samsung
2 Anode 1 N/A N/A
3 Oxalic acid kg $0.65 $0.05 Alibaba
3 PVDF (Indirect) kg N/A N/A Alibaba
3 NMP (Indirect) kg $5.00 $0.60 Alibaba
3 Graphite kg $18.00 $5.21 Samsung
3 Cu Foil kg $10.00 $2.63 Samsung
2 Cathode 1 N/A N/A
3 LiNiCoMnO2 active kg $20.00 $9.85 Samsung
3 Carbon kg $0.60 $0.05 Samsung
3 PVDF kg N/A N/A Alibaba
3 Al Foil kg $5.00 $0.61 Samsung
2 Separator sq m $1.00 $2.89 Polypore
1 Electrolyte kg $40.00 $3.51 Samsung
2 Additives kg TBD TBD Samsung
1 Top insulator 1 $0.02 $0.03
1 Bottom insulator 1 $0.02 $0.03
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15. Mixer Selection
LiNiCoMnO2 active: 12,268,034 kg per year
Graphite: 7,202,896 kg per year
Equipment Supplier: Asada
Cathode prep: 4 x 1000 gallon mixers
Anode prep: 2 x 1000 gallon mixers
Cathode mix: 4 x 1000 gallon mixers
Anode mix: 2 x 1000 gallon mixers
12 operators
2 engineers
2 QC
1 supervisors
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16. Coater Selection
Equipment Supplier: Hirano
Cathode coater:
7 x 30 meter drying zone
7 x NMP abatement
Anode coater:
10 x 30 meter drying zone
26 operators
2 engineers
2 QC
2 supervisor SJSU ENGR297G

17. Calender Selection
Equipment Supplier: Hitachi
Cathode:
3 x 1000mm web calender
Anode:
3 x 1000mm web calender
6 operators
2 engineers
2 QC
1 supervisor
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18. Slitting
Equipment Supplier: Nishimura
Cathode:
3 x slitter (50m/min)
Anode:
3 x slitter (50m/min)
6 operators
2 engineers
2 QC
1 supervisor
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19. Winding
Equipment Supplier: TBD
8 x large format winders
6 operators
2 engineers
2 QC
1 supervisor
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20. Dry Room
1 x 30,000 square foot
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21. Automated Assembly
Equipment Supplier: Hitachi
3 x full automation line
3 operators
2 engineers
2 QC
1 supervisor
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22. Formation
Channels
Capacity: 60A max
Cost: 500$ per channel
# of Channels: 79,621
41 operators
2 engineers
2 QC
3 supervisors
Cell charge/discharge: 20 hours
Extended hold: 21 days
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23. Plant Layout
Material
Stores
Finished
Goods
Mixing
Coating
Cathode
Anode
Converting
Dry Room
Cathode Calendaring and Slitting
Anode Calendaring and Slitting
Offices
Assembly
Formation
1” = 30m
339,770 sq ft
557’ x 610’
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24. Labor
Average wage – Ulsan, South Korea
Operator: $14.77 per hour
Manufacturing Supervision: $22.24 per hour
Manufacturing Engineer: $31.79 per hour
Overhead: 38%
Direct labor cost: $18,208,516
Indirect labor cost: $11,075,320
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25. Yields and Uptime
Capacity: 27 million cells per year
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26. Ramp Plan
Production capacity
2016 – 47%
2017 – 53%
2018 – 73%
2019 – 80%
2020 – 100%
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27. Ramp Plan
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28. Material Costs
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29. Capacity: 27 million cells per year
Cost of Goods
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30. Capacity: 27 million cells per year
Cost of Goods
BMW i3: 96 cells x $30.62 = ~$3000
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31. $1715.60 x 8 = ~$13,725
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32. Assembly: Manual vs Automation
Manual assembly
7 assembly lines
$1.75 million capital
49 operators
90% process yield
Automated assembly
3 automated lines
$9 million capital
3 operators
97% process yield
SJSU ENGR297G

33. Assembly: Manual vs Automation
Manual assembly
7 assembly lines
$1.75 million capital
49 operators
90% process yield
Automated assembly
3 automated lines
$9 million capital
3 operators
97% process yield
SJSU ENGR297G

34. Assembly: Manual vs Automation
Manual assembly
7 assembly lines
$1.75 million capital
49 operators
90% process yield
Automated assembly
3 automated lines
$9 million capital
3 operators
97% process yield
SJSU ENGR297G

35. Assembly: Manual vs Automation
Manual assembly
7 assembly lines
$1.75 million capital
49 operators
90% process yield
Automated assembly
3 automated lines
$9 million capital
3 operators
97% process yield
SJSU ENGR297G

36. Assembly: Manual vs Automation
Manual assembly
7 assembly lines
$1.75 million capital
49 operators
90% process yield
Automated assembly
3 automated lines
$9 million capital
3 operators
97% process yield
$53.5 million per year difference!
SJSU ENGR297G

37. Thank you!