Solutions · Automotive
EV manufacturing, fully connected
From cell incoming inspection to pack EOL test — one platform for traceability, change control, and real-time line visibility across battery, motor, and final assembly.
Key Challenges
Three problems every EV manufacturer hits
These are not theoretical. They come from production floor audits and post-recall root cause analyses we have conducted with our automotive customers.
Challenge
No cell-to-pack traceability
Individual cell serial numbers, formation data, and impedance measurements are lost between incoming inspection, module assembly, and pack integration. When a field recall hits, you cannot trace which packs contain affected cells.
How DFI Solves It
DFI Digital Twin captures cell-level genealogy at every station. Scan a pack serial and retrieve the full tree: cells, module torque values, BMS firmware version, and EOL test results.
Challenge
Engineering changes take weeks
A BMS firmware update requires email chains between R&D, manufacturing engineering, quality, and the supplier. By the time the ECN is signed, three production lots have shipped on the old revision.
How DFI Solves It
DFI PLM routes ECO/ECN workflows in parallel to all stakeholders, auto-populates affected BOMs, and blocks production release until digital signatures are complete. Average ECN cycle time drops from 18 days to 3.
Challenge
Multi-tier supplier BOM drift
Tier-1 suppliers substitute components without formal notification. The manufacturing BOM diverges from the engineering BOM. Quality finds out only after AOI flags an unknown part number.
How DFI Solves It
DFI PLM maintains linked Engineering, Manufacturing, and Service BOM views. Supplier portal submissions trigger automatic where-used impact analysis and revision comparison diffs.
Battery Line Coverage
Every station, every data point
The digital twin mirrors your physical battery line station-by-station. Each stage captures process parameters, quality metrics, and genealogy data in real time.
Cell Incoming
Impedance, OCV, visual inspection
Cell Sorting
Capacity grading, IR matching
Module Stacking
Cell placement, spacer presence
Laser Welding
Weld power, weld depth, visual
BMS Integration
Firmware flash, CAN bus verify
Module EOL Test
Charge/discharge, leakage, HiPot
Pack Assembly
Torque, thermal paste, harness routing
Pack EOL Test
Full-cycle test, BMS calibration, label
Motor and final assembly lines follow the same pattern. Contact us for a line-specific configuration.
Results from automotive deployments
100%
Cell-to-pack traceability
73%
Reduction in ECN cycle time
< 2 min
Time to pull full pack genealogy
4.2%
OEE improvement in first 90 days
Platform modules used
The automotive solution draws from multiple DFI modules. Each is available standalone or as part of the full platform.
“Before DFI, a single recall investigation took our quality team two weeks. Now we pull the full cell-to-pack genealogy in under two minutes.”
VP Quality, VoltaDrive Motors
Read the full case study →Ready to connect your automotive line?
We scope a proof-of-value focused on your highest-impact line. Typical pilot: 6 weeks.