Landscape

Pains

Gains

Battery and Clean Tech Manufacturing

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.

Prototype-to-Production Gap

Cell designs that work in the lab fail at volume. Without structured design transfer processes, teams repeat costly trial-and-error cycles on every new programme.

⚠️ 12–18 month delays are common when scaling from pilot to volume production

Yield & Scrap Visibility

Real-time production data exists in silos — electrode coating, cell assembly, formation and grading systems don't talk to each other, making root cause analysis painfully slow.

⚠️ 30–50% scrap rates in early ramp-up with limited ability to identify root causes

Quality System Immaturity

Teams scaling from R&D lack the structured FMEA, control plan and APQP disciplines that automotive OEMs demand. Quality is reactive, not preventive.

⚠️ PPAP rejections and OEM audit failures delay programme launches by months

Traceability & Regulatory Pressure

The EU Battery Regulation demands full cell-to-pack traceability, carbon footprint data and Battery Passport compliance — but most manufacturers lack the data infrastructure.

⚠️ Non-compliance risks market access across the entire European EV supply chain

Knowledge Silos Between Programmes

Lessons from one cell chemistry or format don't transfer to the next. Design decisions, failure modes and process parameters are locked in individuals' heads or in spreadsheets.

⚠️ Teams repeat the same mistakes programme after programme

Disconnected Engineering & Production Systems

CAD, PLM, MES, test data and ERP operate independently. Engineers waste hours reconciling BOMs, chasing revision status, and manually linking design intent to production.

⚠️ Engineering changes take weeks to reach the production floor accurately

Li-ion Battery Design FMEA

21700 Cell Design Assessment Completed in 12 weeks

How we delivered 200+ hours of battery cell DFMEA workshops using VDA/AIAG 2019 methodology with Relyence tooling — transforming a scaling battery technology team's approach to design risk management.

Case Study -->

Gains You Make With Us

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

Closed Loop Engineering

PLM for Battery Development

Structured product lifecycle management for cell, module and pack programmes — managing BOMs, design iterations, change control and supplier collaboration in a system.

Cell-to-pack BOM management
Engineering change control & revision tracking
Multi-format programme management

Risk Management

FMEA & Quality Engineering

Structured DFMEA and PFMEA delivery using VDA/AIAG 2019 methodology — building the quality disciplines that automotive OEMs expect from day one.

Battery-specific DFMEA & PFMEA facilitation
IATF 16949 & APQP/PPAP alignment
Control plans and SC/CC definition

Better Integration

Production Data & MES

Connect electrode coating, cell assembly, formation, grading and packing systems into a unified production data platform — enabling real-time yield visibility and SPC.

End-to-end production data integration
SPC and process capability monitoring
Automated batch traceability

Enhanced Decision Making

IoT & Predictive Analytics

Deploy sensor networks and analytics across manufacturing equipment to predict failures, optimise energy consumption and reduce unplanned downtime during ramp-up.

Equipment condition monitoring
Energy consumption optimisation
Predictive maintenance for critical assets

Consistent Data

System Integration

Connect PLM, MES, ERP and test systems to create a continuous digital thread from cell design through to field performance — eliminating data silos and manual handoffs.

PLM–MES–ERP integration
Automated BOM transfer & synchronisation
End-to-end engineering change flow

Global Site Visibility

Traceability & Compliance

Build the data infrastructure for EU Battery Regulation compliance, Battery Passport requirements and carbon footprint reporting — before the deadlines arrive.

Cell-to-pack traceability architecture
Audit-ready compliance documentation
Battery Passport data framework

FAQs

Common questions UK battery and clean tech manufacturers ask about working with TJ Digital Systems

Do you work with UK battery and clean tech manufacturers?

Yes - we work with UK battery and clean tech start-ups and scale-ups on the manufacturing systems side: PLM (via CIM Database from CONTACT Software), MES, quality systems and manufacturing assessment. We focus on the general manufacturing infrastructure, not on cell chemistry or electrochemistry. If you need specialist battery formulation expertise, we will be upfront about that and can recommend partners.

What manufacturing systems do UK battery and clean tech manufacturers typically need?

Most UK battery and clean tech operators need PLM for product and process traceability, MES for shop-floor execution and quality systems for ISO 9001 or IATF 16949 compliance. We implement these using CONTACT Software (CIM Database PLM and Elements for IoT) as our main toolkit, plus complementary partners where specialist sector features are required.

Can you support clean tech and battery start-ups through scale-up?

Yes - we typically begin with a Manufacturing Assessment to map the scale-up requirements and identify where investment will deliver the biggest impact. We then implement PLM and MES with a phased approach so the systems grow with the business rather than being over-spec’d on day one.

Where does TJ Digital Systems’ experience end in battery and clean tech?

We are explicit about where our expertise ends. We know manufacturing operations, PLM, MES, automation and quality systems. We are not chemistry specialists, electrochemistry consultants or gigafactory-specific advisors. Start with a free Manufacturing Discovery Session and we will be honest about whether we are the right fit for your operation.