Electric vehicle (EV) supply chains are being disrupted by automation, from the design stage to final delivery. The demand for EVs globally is ramping up, and the use of automation technology allows for more EVs to be produced at lower costs while increasing manufacturing efficiency, productivity, and consistency. Automation simplifies complex manufacturing tasks and compensates for labor force availability by deskilling some processes.
The global EV market registered nearly 14 million new electric cars in 2023, taking the total number of EVs on the road to 40 million. This also marks impressive growth closely aligned with the Global EV Outlook 2023 forecast—a 35% year-on-year increase, with sales in 2023 being 3.5 million higher than in 2022. Electric car registrations in India jumped 70% year-on-year to 80,000, driven by supportive government incentives and the popularity of new and improved models.
Automation driving the EV revolution
Automation is the major catalyst for innovation in the EV industry, affecting all stages of the supply chain. It is in battery manufacturing where automation helps uphold such qualities as consistency, quality, and precision, crucial for the production of high-performance batteries in electric vehicles. Autonomous driving technologies are being developed to improve safety and efficiency during EV manufacturing. These technologies depend on advanced sensors and systems, which cannot function without automation. Lastly, automation improves efficiency and reduces costs associated with EV manufacturing processes. Completely automated factories can greatly increase production capacities while maintaining high levels of quality and accuracy.
Some of the key areas of automation in the EV supply chain are:
Robotics: There are several ways robotic automation is used throughout manufacturing. For example, robotics can perform complex operations faster and more accurately than humans thereby ensuring product uniformity whilst avoiding human error during assembly. In painting, robots provide even coverage which prevents corrosion besides enhancing its appearance. In warehousing, robotics automates component handling and storage, making inventory management and retrieval easy.
Automated Guided Vehicles: This refers to vehicles that transport materials around factories or warehouses independently. These vehicles follow predefined paths to move parts and components to various locations. AGVs streamline material flow, ensuring that the right components are delivered to the right place at the right time. This takes away dependence on human labour and thus eliminates errors and delays. By smoothing out logistics, AGVs contribute to a more efficient manufacturing process by providing a smooth flow of operations and faster turnaround.
Machine Learning and Artificial Intelligence: Machine Learning and Artificial Intelligence analyse large amounts of data to forecast accurate demand, thus enabling manufacturers to align their production schedules with market needs. AI-driven systems can further optimise inventory levels to ensure that materials are available when needed but not overstocked. These technologies also assist in predictive maintenance by identifying potential equipment failures beforehand and, therefore, minimising downtime. By providing data-driven decision-making, machine learning and artificial intelligence help manufacturers optimise efficiency, reduce waste, and achieve better operational performance.
3D printing: 3D printing is an on-demand production of parts and components that reduces the necessity for having big inventories and storage facilities. This allows for flexibility to respond to design changes and custom needs from customers. 3D printing is able to achieve complex geometries that may not be possible or are highly difficult to manufacture using traditional techniques, often at lower cost with shorter lead times.
Supply chain visibility: Automation technologies facilitate better visibility across the supply chain, allowing real-time insights into levels of inventory, shipment status, and other key metrics. Such visibility enables manufacturers to trace the movement of materials and components throughout the entire supply chain for transparency and accountability. It gives better insights into the manufacturer’s supply chain processes, and through these, much wastage is sorted out, and efficiency is gained. Moreover, supply chain visibility promotes ethical sourcing by enabling a company to trace the origin of its materials for compliance with regulatory standards.
Enhancing battery production through automation
Advanced transport systems, such as automated conveyor belts and autonomous cart systems, are important in enhancing the efficiency of producing batteries. These systems move parts quickly and reliably down the line, speeding up the process. Less manual work and easy transport help factories hit high targets and cut cycle times. Plus, these machines keep the assembly of cells precise and seals tight, ensuring every unit is safe and works perfectly. This precision is crucial for the reliability and performance of the batteries because even slight deviations can affect their efficiency and safety.
Furthermore, automation boosts safety in production with thorough automated tests at each stage. These tests ensure that the batteries work well and are safe, spotting issues early and reducing defects. Other tests include checks on electrical performance and heat stability to ensure only safe, high-quality batteries go to market. Quality checks benefit from traceability systems, which keep detailed records of each battery’s production path. This thorough logging lets manufacturers track quality continuously, quickly resolve issues, and implement improvements.
The bottom line is that automation offers robust solutions, allowing manufacturers to do more with existing resources and providing a foundation for future growth. By improving efficiency, reducing costs, and enhancing quality, these technologies enable dynamic advancements in production lines, making it possible for manufacturers to react rapidly to shifts in design specifications and market trends, thus remaining efficient and competitive in an evolving industry.
