TABLAMI Key machine in the manufacturing of lithium-ion batteries

Compliance and optimization of a TABLAMI machine for the manufacture of lithium-ion batteries

Context

TABLAMI is highly automated lithium-ion battery manufacturing equipment designed by Korean manufacturer Wonik.

This machine integrates several critical stages of the cell manufacturing process, including welding, assembly, forming, and inspection operations. It is made up of several hundred interconnected automatic mechanisms, robots, and control systems.

Installed on a battery production line, this machine presented significant limitations in terms of regulatory compliance and operational performance.

Initial analysis revealed that the original design did not fully comply with the requirements of the European Machinery Directive as well as the UK’s Provision and Use of Work Equipment Regulations (PUWER).

Furthermore, during the ramp-up phase, operators had to frequently access the interior of the machine to make adjustments and fine-tune the process. Safety requirements then demanded complete isolation of energy sources, resulting in prolonged shutdowns and substantial production losses.

For several months, these repeated interruptions severely penalized line performance and limited the scaling of production capacity.

Challenge

The objectives of the project were:

Ensure equipment compliance with European and British regulations.
Significantly reduce downtime linked to operator interventions.
Improve plant availability and production performance.
Avoid a complete overhaul of the machine, which would have required several months of line shutdown and a significant investment.

My role

I assumed the role of leader of the task force dedicated to compliance and improving TABLAMI’s performance.

For almost four months, I led the studies, the preparation of the work and their completion on site, coordinating all the stakeholders:

Health, Safety and Environment
Production
Processes
Maintenance
Engineering in Mechanics and Automation
Purchases
Finance
Wonik OEM Supplier

This international coordination represented a major challenge given the differences in technical culture, business vocabulary and working methods.

Solution implemented

An in-depth functional analysis was carried out with the operational teams in order to identify the root causes of recurring shutdowns and the levers for improvement.

The main actions implemented included:

Mechanical modifications

Adaptation of several devices to facilitate adjustment and maintenance operations.
Improved accessibility to intervention areas.
Strengthening operator safety.

Electrical modifications and automation

Complete revision of security logic.
Optimization of operating sequences.
Updating control systems.
Installation of security sensors, laser scanners and new security loops.
Compliance of security functions in order to achieve a PL_d performance level in accordance with EN ISO 13849.

Correction of control software

More than fifty programming anomalies were identified and corrected in collaboration with the manufacturer.

Each problem was analyzed, tested and validated in order to improve the stability and robustness of the equipment.

The work was carried out during scheduled maintenance periods (TPM) as well as during the 2026 Easter holiday production shutdown in order to minimize the impact on operations.

Results

The modifications implemented have led to a spectacular improvement in machine performance:

Removing the main bottleneck of the production line.
Significant improvement in OEE and PPM indicators.
- Increased production capacity from 1,000 to 6,000 cells in just three weeks after recommissioning.
- Achieved performance above 13 ppm during intensive load ramp-up tests.
Total cost of alterations less than £50,000 (excluding internal labor costs).
Avoidance of a complete overhaul representing several months of production shutdown and a much higher investment.

Added value

This project illustrates the effectiveness of an approach combining:

Machine safety
Functional analysis
Industrial automation
Process engineering
International project management
Optimization of industrial performance

Through a strategy of targeted, low-cost modifications, it was possible to simultaneously improve regulatory compliance, operator safety and production performance, while significantly accelerating plant ramp-up.

Key result

6x production increase within 3 weeks
Investment < £50,000
Full compliance with the Machinery Directive and PUWER
Removal of the line’s main bottleneck