OEM and Cell manufacturer – EV Applications – Benchmarking and cost analysis for Giga scale plants 33GWh in Europe and North America
Project Overview
Bonsai Technology partnered with a leading automotive industry client to conduct an in-depth analysis of cost simulation and benchmarking for manufacturing plant costs (OPEX/CAPEX), with a focus on identifying limiting factors and operational bottlenecks. The project specifically addressed Giga scale battery production plants with capacities of up to 35GWh, supporting the client in optimizing their cost structure and production capabilities.
Client Challenges
- Limited understanding of advanced manufacturing technologies and best practices in the battery industry.
- A cost model built predominantly on academic research, lacking real-world validation and insights from industry experts.
Solution Provided
Bonsai Technology delivered a comprehensive strategy and analysis to address these challenges:
- Cost Model Analysis: Conducted a thorough examination of the client’s existing cost model to identify key insights and areas of improvement.
- Model Refinement: Integrated the client’s input into Bonsai Technology’s advanced cost model, exposing discrepancies and misalignments that could affect accuracy.
- Detailed Examination of Misalignments: Analysed and identified specific areas where the client’s cost projections did not align with real-world data.
- Manufacturing Challenges and Bottleneck Identification: Defined and examined constraints within high-volume battery production, focusing on efficiency, technology adoption, and scalability.
- Workshops with Technology Providers: Facilitated collaboration with cutting-edge technology providers to assess and integrate emerging technologies, positioning the client to overcome manufacturing challenges and gain a competitive edge.
- Competitive Positioning Scenarios: Developed multiple scenarios to evaluate the client’s position relative to key competitors in Europe, North America, and Asia. This analysis was based on levels of manufacturing technology adoption and innovation strategies.
Implementation Process
Throughout the project, Bonsai Technology maintained close collaboration with the client’s team to ensure seamless execution:
- Stakeholder Engagement: Worked alongside industry experts and key stakeholders to gather market intelligence and validate critical assumptions.
- Supplier Evaluation and Partnership Negotiation: Conducted a comprehensive review of suppliers and facilitated partnerships, ensuring a secure and efficient supply chain.
- Advanced Cost Modelling: Utilized advanced simulation and forecasting techniques to project operational costs under different scenarios, evaluating the financial viability of various strategies.
Project Outcome
By leveraging our deep industry expertise and collaborative approach, Bonsai Technology provided the client with actionable insights and tailored strategies to significantly enhance their competitiveness in the rapidly evolving battery production landscape for electric vehicle applications.