MANUFACTURING

Uncompromising quality control lies at the very heart of Kais’s manufacturing philosophy. Whether it’s battery pack or BMS manufacturing, we create lasting value for our customers through strict IPQC and lean manufacturing.

diverse production lines

Production CAPACITY

Kais provides fully integrated sketch-to-scale services with production capability of processing millions of batteries and BMS each year. Kais production floor is equipped with multiple production lines to handle different types of customer purchase order, ranging from manual line to fully automatic production line complemented with a preprocessing line.

 

Battery Pack Production Capacity

BATTERY PACK

400 PPM

pieces of cylindrical cell per minute

  • x 1 Automatic Line (100 PPM)
  • x 5 Semi-automatic Manual Line
  • x 2 Preprocessing Line
  • x 1 Module Production Center
  • x 2 Manual Line (50 PPM)
  • x 1 Wire-bonding Line (20 PPM)

SMT Capacity

PCBA

4.5 Million

pieces of SMD components per day

  • x 3 SMT line with daily capacity of1.5 Million points/line
  • Lead-free and RoHS process engineering
  • Minimum components packaging down to 01005
  • Minimum mounting spacing 0.1 mm
  • BGA mounting spacing 0.1 mm, 256 balls

MANUFACTURING EXCELLENCE

BATTERY PACK MANUFACTURING PROCESS AND EQUIPMENTS

Digitalization is the secret receipt to Kais superior quality control. Every product has to go through various tests and cleansing throughout the production process, and the result of each test is tracked and recorded to the MES system for monitoring and analysis. These big data lays the foundation for our constant optimization of the production line.

 

Kais master battery pack facility.

 

Tray load with CCD positioning, angular position ≤0.5mm.

 

Auto insulation paper attaching, CCD positioning, precision within 0.2mm.

 

Plasma surface cleansing for both cathode and anode sides.

 

Auto QR code scan for cell data check and upload to MES (cell info position fixed in module).

 

OCV/IR test, OCV precision 1mV, IR precision 0.1 mΩ and MES tracking.

 

Auto server controlled assembly with positioning, 100 PPM efficiency and accuracy ±0.1 mm, single cell traceability.

 

Robotic module welding with a 100PPM efficiency and accuracy ±0.1 mm.

 

Welding pressure check for each welding point, pressure value upload to MES.

 

Comprehensive data collection (welding power, current, rate, IR value) and upload to MES.

 

HIGH SPEED PRECISION SURFACE MOUNTING TECHNOLOGY

PCBA MANUFACTURING PROCESS AND EQUIPMENTS

Kais provides PBCA one-stop-shop total solution service , our production line is equipped with world-class express high precision equipment, such as Panasonic surface mounting system, Heller reflow soldering machine etc. Providing service from design, SMT manufacturing to assemble & testing. Digitalization is the centerpiece of our optimization efforts, In our relentless pursuit for greater consistency and efficiency, we’ve continued to invest in high precision equipment and robotic soldering equipment, improving the connectivity of our equipment, process control, and personnel.

 

Kais Suzhou SMT facility overview.

 

Lean components and material handling process with optimized inventory accuracy and OEE.

 

Solder paste printing with in-house complex stencil design capability.

 

Separate Solder Paste Inspection (SPI) process to enable a thorough inspection.

 

Panasonic NPM series high-speed surface mount placement.

 

Reflow soldering with designated reflow profile to form electrical solder connections.

 

Automated Optical Inspection (AOI) checks for component presence, type/value and polarity.

 

Lean stencil and jig management streamline operations.

 

Electrostatic Discharge (ESD) simulator for verifying BMS electrostatic discharge immunity.

 

X-Ray inspection on underneath components such as BGAs and verifying the solder holes.

 

Control for quality

ENVIRONMENT CONTROL

The importance of environmental control is often underrated in battery pack manufacturing. The temperature and humidity of the factory are both critical factors affecting the capacity and performance of the battery. The fluctuating temperature will impact the final rated capacity of the batteries. High humidity will cause metal components to rust, while low humidity will cause electrostatic discharge (ESD).

 

Well organized workshop with comprehensive tool sets

 

High power smoke exhaust system

 

Digital humidity and temperature monitoring

 

Modular anti-collision rails

 

EXHAUSTIVE ANTI-ESD CONTROL

TOTAL ELECTROSTATIC DISCHARGE PROTECTION

ESD is a critical concern in electronic manufacturing, because it has a significant impact on the quality of the final product, and these impacts are often undetected until much later into a product’s life cycle.

Kais has adopted a systematic approach to eliminating ESD from our production floor, from electrically conductive workwear such as Anti-ESD wristband, protection shoes, grounded carts, to conductive materials used in the floor, ceiling, and wall, as well as anti-static gate.

 

Anti-static wristband

 

Anti-static access control

 

Anti-static ground cords on handling carts

 

FULL PROCESS MES TRACKING SYSTEM

INTEGRATED MANUFACTURING EXECUTION SYSTEM

Kais’s incessant pursuit of quality is inseparable from its meticulously designed Manufacturing Execution System (MES). The system provides real-time feedback and all component traceability for in-depth optimization.

The MES monitors every product as it moves through our production line, providing essential information about its material and component makeup, while incorporating the results from in-process tests. This allows us to track any faults in a product straight back to its origin. It also collects data to support our production optimization efforts.

 

In-house designed MES system as our requirements outgrew the commercially available options.

 

First-In-First-Out and process-oriented material flow transparency.

 

LEARN MORE ABOUT OUR TESTING LABS AND CAPABILITIES

 

The CCD solder joint detector is an automatic equipment for lithium battery processing, which has the functions of automatic positive.


TESTING & STANDARDS