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Enhancing quality management through semi-automation and digital integration for solar energy solutions
Author(s)
Cornelius, Robyn
Date Issued
2026
Type
master thesis
Publisher
Cape Peninsula University of Technology
Abstract
This study investigates how semi-automation and digital integration can strengthen quality management within a start-up battery manufacturing environment producing lithium-ion battery packs for solar energy systems. Start-up manufacturers often rely heavily on manual processes, which increases variability, defect risk, and inefficiencies. The research therefore examines whether introducing semi-automated welding and digital integration tools can meaningfully improve product quality, process consistency, and operational efficiency. A mixed-methods design was adopted, combining quantitative production data from torqued (manual) and welded (semi-automated) assembly lines with qualitative insights from audit reports, observation logs, and internal quality documentation. The quantitative findings show that semi-automation significantly enhanced process stability. Although welded packs recorded more defects in absolute numbers, they represented far lower defect rates when normalised to output. Variability in electrical performance decreased markedly, with statistically significant improvements across discharge, charge, and final-charge voltage stages. Real-time monitoring data further indicated narrow voltage spreads and low internal-resistance variation, demonstrating equipment stability and consistent weld integrity. Operational efficiency also improved. First Pass Yield for welded packs stabilised close to 100%, while the manual line continued to fluctuate. Throughput on the welded line exceeded 350 packs per month compared to fewer than 100 on the manual line. Time-study results confirmed an overall 14% reduction in assembly time, with the greatest savings achieved in joining stages where laser welding replaced labour-intensive manual operations. Although scrap costs were initially higher for welded packs due to early learning-curve defects, machinedriven faults were more systematic and easier to eliminate than persistent human-error variation. Qualitative findings supported these results by highlighting how semi-automation reduced reliance on operator skill, improved traceability, and strengthened process control in a context where documentation consistency, training gaps, and fragmented data previously hindered quality performance. Overall, the study demonstrates that semi-automation and digital integration substantially enhance quality management in start-up battery assembly environments. Improvements in process stability, defect predictability, throughput, and real-time monitoring show that even under resource constraints, digital and semi-automated systems offer a practical and scalable pathway toward higher quality and operational excellence.
Additional information
Thesis (Master of Engineering (Quality))--Cape Peninsula University of Technology, 2026
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Name
Cornelius, R_230262856 (2).pdf
Size
1.4 MB
Format
Adobe PDF
Checksum
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