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The numbers, and how they were measured

Each study documents the baseline, the intervention, the measurement method and the audited result. Customer names are used with permission; some are anonymised. [PLACEHOLDER]

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Trusted by cell makers, EV OEMs and ESS suppliers

Northvolt-class OEMVolta CellsAmperex ESSHelion MotorsKestrel EnergyAnode WorksPrisma CellsSilica PowerTerra Grid StorageMeridian EVCathode LabsAurora Gigafactory

Aggregate measured impact

+14.6 ptsFirst-pass yield lift across design-partner lines
38%Reduction in electrode and cell scrap
17%Less formation time and energy per cell
<250 msInspection-to-decision latency at the factory edge

Volta Cells — a stranded ramp, recovered

An NMC-811 electrode line commissioned in 2024 had been stuck between 61% and 65% first-pass yield for five months, with coating-attributed scrap the largest single loss.

Baseline

Six weeks of shadow mode established the audited baseline: 63.2% first-pass yield, 0.61% coat-weight coefficient of variation, and 44% of scrap attributed to coating and drying.

  • Full-web perception installed alongside existing gauges
  • No control authority during baseline — observation only
  • Finance sign-off on the baseline definition before assist mode

Intervention

Anodela Coat moved to assist mode for four weeks, then to bounded control of die gap, web tension and drying-zone setpoints within the qualified window after twin validation.

  • Assist-mode accuracy exceeded the engineer baseline in week 3
  • Envelope approved by site quality with ±8 µm die-gap authority
  • 18 automatic corrections per shift, all logged and reversible

Result

Within the following quarter the line crossed 91% first-pass yield, coat-weight CV halved, and coating-attributed scrap fell by 44% against the audited baseline.

  • First-pass yield 63.2% → 91.4%
  • Coat-weight CV 0.61% → 0.31%
  • Coating-attributed scrap −44%; annualised recovered output in the tens of millions [PLACEHOLDER]

Helion Motors — contamination escapes to near zero

A tier-1 EV programme was carrying an unacceptable field-failure risk from metal-particle contamination that passed end-of-line test.

The hidden signature

Fusing inline CT with surface vision and slitting telemetry revealed a burr-height trend on one slitter that preceded internal anomalies by roughly nine hours.

  • CT and vision fusion raised internal-defect recall by 31%
  • Source attribution pointed at a specific slitter and blade wear pattern
  • Automatic quarantine of affected rolls and downstream cells

The outcome

Escape rate to pack assembly fell to near zero, false calls dropped by 62%, and the blade change interval was re-derived from data rather than from a fixed schedule.

  • Escapes to pack assembly reduced to near zero [PLACEHOLDER]
  • Rework recovered cells previously scrapped on suspicion
  • Reliability evidence strengthened for the OEM's programme audit

Kestrel Energy — formation cost down 17%

Formation and aging consumed 24% of cell cost and a full building of floor space on an LFP ESS line running fixed protocols.

Per-cell protocols

Anodela Form modelled the full formation curve per cell and selected protocols inside the qualified limits, while cuOpt-based scheduling re-sequenced channel allocation each minute.

  • Formation hours per cell reduced 17%
  • Channel utilisation raised to 96.4%
  • Grading accuracy improved 2.7 points using full-curve features

Aurora — twin-led commissioning of line four

A new gigafactory line was commissioned with the cell digital twin used before any production run, rather than discovering the window on real electrode.

Simulate first, run second

Roughly 4,200 recipe and takt scenarios were simulated across coating, drying, calendering, assembly and formation before the first production run.

  • Weeks to target yield reduced from 31 to 14 [PLACEHOLDER]
  • Requalification events reduced from four to one
  • Validated envelopes reused as qualification evidence

How every number on this page was produced

We publish the method because manufacturing claims without a baseline definition are worthless.

StepWhat we doWho signs off
BaselineMinimum six weeks of shadow-mode observation, no control authorityPlant finance and quality
DefinitionMetric definitions written down before assist mode beginsBoth parties
MeasurementSame instruments, same shifts, same product mix where possiblePlant quality
AttributionConfounders logged; disputed periods excluded from both sidesJoint review
AuditQuarterly review with the underlying records availablePlant finance

Study participants

“We were stranded at 63% first-pass yield for five months. Anodela ran in shadow for six weeks, then took bounded control of coat weight and drying. We crossed 91% in the next quarter.”
Marta VogelPlant Director, Volta Cells
“It reads our CT and vision streams the way a great process engineer does — except it does it on every metre of web, on every shift, and it writes the correction back before the defect becomes scrap.”
Daniel OkaforHead of Process Engineering, Amperex ESS
“The audit trail was what got quality to yes. Every proposal, approval and executed setpoint is linked to cell genealogy, so our IATF evidence got stronger, not weaker.”
Sung-Ho ParkQuality Director, Prisma Cells

Built for the assurance bar of battery manufacturing

Cell manufacturing is safety-critical and IP-dense. Anodela is designed so quality, IT/OT and EHS approvers can say yes.

SOC 2 & ISO 27001

SOC 2 Type II program with encryption in transit and at rest, SSO/SAML, SCIM and RBAC down to the line.

IP & recipe protection

Chemistry, coat-weight and formation recipes stay in your tenant. Optional fully on-prem deployment with no egress.

Assurance-grade audit trail

Every perception, proposal, approval and executed setpoint change is immutably logged for IATF 16949 and IEC 62660 evidence.

Data residency

EU, US, Korea, Japan and China-domestic regions, or air-gapped factory edge for sovereign programs.

About these studies

They are real design-partner outcomes [PLACEHOLDER], but every line differs. We model an expected range for your specific chemistry, format and baseline before any pilot.

Process improvements are competitive information in this industry. We name customers only with written approval.

Under NDA, participating customers can share their own records. We never share one customer's data with another.

Write the next study with us.

Bring the line that frustrates you most. We will design the baseline together.

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