Management of Specialized Packaging Challenges for Lithium-Ion Batteries - A Case Study on Volvo Group Trucks Technology’s Prototype Process

Abstract

The rapid growth of the Electric Vehicle (EV) sector, coupled with ongoing electrification efforts, underscores the critical importance of Lithium-ion Batteries (LIBs) and the necessity for specialized packaging to ensure their effective management. Despite the significance of LIBs, the literature reveals a research gap within the Automotive Development Process (ADP), particularly in managing specialized packaging for LIBs in prototype processes. This thesis addressed this gap by examining the challenges associated with specialized packaging in the automotive prototype context, identified those specifically relevant to LIBs, and explored the integration of 20 Lean Tools to manage these challenges. Using a case study research design, data were collected within Volvo Group Trucks Technology (GTT), through three rounds of expert inputs, comprising individual interviews, a focus group discussion, and a survey. Analysis of the collected interview data revealed 24 challenges related to specialized packaging, which were categorized into four distinct themes: Organizational, Planning, Logistical & Operational, and Safety & Quality. Through analysis of the focus group discussion, 13 challenges were identified within the four themes, as applicable to LIB specialized packaging and subsequently formed the foundation of the survey. Furthermore, the application of the Ordinal Priority Approach (OPA) to the survey data enabled identification of Lean Tools appropriate for addressing the four identified themes of challenges. The results demonstrated that Lean Tools, with particular emphasis on Standardized Work, exhibited broad applicability across all themes and received the highest relative prioritization. Lastly, the analysis contributed to the establishment of a structured method to facilitate the implementation of these tools in the management of specialized packaging within the studied prototype process. Keywords: