State-of-the-Art Facilities

Electrochem’s world-class facilities provide a bi-coastal footprint located in Raynham, MA – Clarence, NY – and Beaverton, OR.

Our manufacturing facility located in Raynham, Massachusetts is a state-of-the-art building, designed with the environment, our customers and future growth in mind. Built on 20 acres of land, the 82,000 square foot facility is triple the size of the previous facility and employs over 300 dedicated associates including seasoned design, mechanical and electrical engineers and skilled production personnel. Centered around numerous high-tech battery and engineering-driven businesses, Electrochem is proud to be a part of this progressive technology community.

Our Raynham facility provides the following attributes:

• The ability to expand production to meet the growing demands of our existing and future customers, along with an enhanced infrastructure to support the introduction of new automation systems and technology solutions.
• Unparalleled amenities including advanced R&D, rapid prototyping and testing laboratories.
• Enhanced safety for associates and the environment, with fortified housing, state-of-the-art fire suppression systems and improved tactical layouts and placements of our electrolyte, cathode and dry rooms.
• A business sensible green facility that reduces emissions and power consumption with high efficiency HVAC and lighting systems, advanced automation and control systems and 10,000 square foot green roof.

The acquisition of Micro Power Electronics, Inc., in December of 2011, provides another 80,000 square feet for domestic manufacturing in Beaverton, Oregon. These world-class facilities possess the skilled resources, R&D and production tool sets that make our name synonymous with reliability and quality-these complementary facilities enable Electrochem to offer the following to our customers world-wide:

• Test and validation (Click here to learn more)
• Asian manufacturing facilities for high volume products
• Continuous improvement, lean manufacturing, and Just in Time (JIT) product delivery
• Pull system and KanBan control implemented for RM and WIP
• Soldering and welding reliability second to none- IPC 610 Welding standards
  
• Strategic partnerships with top tier cell manufacturers, IC vendors and plastic manufacturers
  
• Risk mitigation of a potentially faulty manufacturing process can be achieved via Process Failure Mode and Effect Analysis (PFMEA) of the manufacturing process
• Production teams built around specific customers
• All products manufactured by Electrochem are compliant with UN/DoT, RoHS, and WEEE guidelines when appropriate
• Eight Maccor test chambers (with 500+ test channels) to profile cell and pack performance
  
• Cell and pack qualification in production
• Individual cells that can be graded and matched prior to pack assembly
• Packs that can be cycled for fuel gauge calibration prior to shipment
• Packs that can be cycled and screened prior to shipment

Electrochem's battery, charger and power supply quality is delivered through the following processes:

• Maintaining one of the lowest Defects Per Million (DPM) rates in the entire portable power industry (less than 600 DPM)
• Risk mitigation of a potentially faulty manufacturing process can be achieved via Process Failure Mode and Effect Analysis (PFMEA) of the manufacturing process
• Risk mitigation in the design process is achieved with Design Failure Mode and Effect Analysis (DFMEA)
• Identification and traceability is established by the manufacturing order and is maintained for each product order, recording, assembly, inspection, and test steps
• Traceability enables Electrochem to track and pinpoint the affected product (unfinished or finished product) within and outside our manufacturing facilities
• Build in quality with next step inspection, final production tests and sign-offs on each production run
• Generation and maintenance of Design History Files (DHF), and Device History Records (DHR). DHFs include any records which describe the design history of a device — design review notes, verification plan and results, validation plan and results, FMEA results. DHRs include documentation affiliated with production — test reports, test data, signed build documents, Certificate of Compliance (CoC), and quality assurance checklist
• Quality process automation, design and process control, document control, and inspection control is managed through the Pilgrim Quality Software