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Process-Validation
First, the logistics process proposed by the customer had to be validated. Batches of 24 battery modules each were securely packed in cardboard boxes on multiple levels and shrink-wrapped; each module weighed approximately 30 kg.
Opening the boxes, unpacking and repacking the modules, conducting a visual inspection for known external damage, sorting out non-conforming (NOK) parts, and digitally documenting the OK/NOK quantities along with defect images: that was the core process.
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Organization of Custom Lifting Aids
Lifting aids were required to handle the 30-kg battery modules. The repackaging facility had not been finalized until shortly before the project began, so the customer’s overhead cranes could not be reliably scheduled.
EuroQ therefore deployed five of its own gantry cranes, which could be positioned flexibly. Two employees worked under each crane, transferring the modules from the cardboard boxes to the load carriers provided by the customer.
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ESD-Standards
At the time of the project, the modules were individually encapsulated, with their poles covered, and had not yet been interconnected. Separate workstation grounding was therefore not necessary. ESD standards were followed, and high-voltage safety training (Level S/E) was a requirement for all employees. Handling was comparable to that of a conventional 12-volt battery, but the sensitivity of the individual modules was different: despite sturdy cardboard packaging, minor damage occurred during transport.
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Definition of Defect Patterns for Quality Control
For quality control purposes, visible shipping damage to the modules was defined in terms of specific defect patterns and documented as inspection criteria for all employees. The list was not static: if new damage characteristics emerged during ongoing operations, it was expanded. Over the course of the project, this resulted in a robust library of defect patterns based on actual findings.
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High-Voltage Safety
Suspicious modules were moved to safety boxes, which are compact fire suppression containers designed for battery cells, modules, and packs.
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Waste Disposal
The composite packaging had to be disposed of in a complex process, with each material sorted separately: cardboard, plastic film, Styrofoam inserts, and cardboard tubes. For each shift, two employees were assigned exclusively to sorting and disposing of the waste by type.
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Digital Documentation
The documentation was handled directly through the EuroQ app: After each shift, the customer received a complete overview of the processed modules and pallets, OK/NOK figures, and damage details broken down by specific damage characteristics.
