Semiconductors

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Clean Tech & Batteries

Scaling the technologies that power the energy transition

The battery & clean tech sector is scaling at breakneck speed — building giga factories, qualifying new chemistries, and ramping production while simultaneously establishing the quality systems and process controls that mature industries take decades to develop. We help clean tech manufacturers scale right the first time.

The Clean Tech & Batteries Landscape

30%

Yield Improvements

Through advanced process control and integrated system connectivity

30%

Less Downtime

Through planned and preventative maintenance activities

25%

Faster Ramp-Up

Reduction in process and production ramp-up time when using pre-integrated partner solutions

Pains Holding You Back

The industry's combination of extreme precision, massive capital investment, and relentless technology evolution creates unique pressures.

Production Ramp-Up

Moving from pilot lines to giga scale production while maintaining yield and quality. Most giga factories take 3-5 years to reach design capacity.

Average gigafactory utilisation is only 40-60% in the first 2 years

Yield & Scrap Rates

Managing scrap rates that can exceed 30% during early production while systematically improving process capability and reducing waste.

Battery scrap during ramp costs £50-100M per giga factory annually

Automotive Quality Standards

Meeting IATF 16949 and customer-specific requirements from automotive OEMs who demand the same quality maturity as established Tier 1 suppliers.

OEM qualification takes 12-18 months requiring extensive evidence

Talent & Knowledge Gap

Building a skilled workforce in a sector where battery manufacturing expertise is scarce and most knowledge exists in a handful of Asian producers.

EU battery sector needs 800,000+ skilled workers by 2030

Supply Chain Traceability

End-to-end traceability from raw materials through cell production to pack assembly, required for both quality and EU Battery Regulation compliance.

EU Battery Regulation requires full supply chain due diligence from 2025

Sustainability

Measuring and reducing the carbon footprint of battery production to meet customer requirements and the EU Battery Carbon Footprint Declaration.

Battery carbon footprint thresholds become mandatory from 2028

Li-ion Battery Optimisation

Ramp-up from 1,000 to 100,000 units in under 12 months

Implemented comprehensive Manufacturing Discovery Program addressing systemic Product, Process and Production inefficiencies. Achieved 90% yield, 100% stakeholder collaboration, and implementation of a structured methodology Process FMEA.

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Gains You Make With Us

Practical solutions for organisations where nanometres matter and minutes of downtime cost millions.

Accelerate Ramp-up

Production Management

Structured ramp-up programmes that accelerate time-to-volume by establishing process control, quality systems, and digital infrastructure from the start.

Run-to-run control optimisation
Fault detection & classification (FDC)
SPC & process capability analysis

Reduced Downtime

Predictive Maintenance

Move from reactive to predictive maintenance using condition monitoring, analytics, and AI to prevent failures before they happen.

Equipment health monitoring
Predictive maintenance models
Spare parts optimisation

Better Products

Yield Analytics & Management

End-to-end yield management systems that correlate process, metrology, and test data to rapidly identify and resolve yield-limiting mechanisms.

Wafer-level yield mapping
CAPA management systems
Defect Pareto & root cause analysis

Consistent Processes

Fab Data Infrastructure

Build the integrated data platform that connects your MES, equipment, metrology, and test systems into a single analytical environment.

SEMI standards integration (SECS/GEM, EDA)
Data lake architecture
Real-time dashboarding

More Units Per Hour

Cycle Time Reduction

Optimise WIP flow, reduce queue times, and improve scheduling to get wafers through the fab faster without compromising quality.

WIP flow optimisation
Bottleneck identification
Lot prioritisation systems

Site Visibility

Quality & Compliance

Roll out consistent processes, KPIs, and digital solutions across all your manufacturing sites for better product quality.

Traceability & lot genealogy
Customer audit preparation
FMEA & control plan management

Clean Tech & Batteries

The Clean Tech & Batteries Landscape

Yield Improvements

Less Downtime

Faster Ramp-Up

Pains Holding You Back

Li-ion Battery Optimisation

Gains You Make With Us

TJ Digital Systems

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