Hello everyone, I'm Wu Junyu. I joined Bosch in 2015 and have held positions as a BPS engineer, production supervisor, and production manager. In October 2023, I transferred to RBCW, responsible for the production of the 48V Gen2 battery.

The story began in October 2023, when the management decided to establish the fourth 48V Gen2 battery production line worldwide at RBCW, which is also the first in China. The purpose is quite clear: To minimize the delivery backlog to Mercedes-Benz China and bring the challenging battery as well as PS business situation back on track. Joining this project brought us both excitement and unprecedented pressure. The first challenge is a short deadline, as the biggest delivery gap for our customer is in the first half of 2024. This left us with very limited time to design, install, and commission the production line, requiring our team to compress all schedules as much as possible. Moreover, the product design and production process for the 48V Gen2 battery was quite complex, including multiple processes like green laser welding and dispensing, which would necessitate the team to learn and fully understand these processes. Overall, we were up against tight deadlines and significant workload.

That time, in hindsight, every day is a race against time. We started designing and manufacturing the stations in early October, and by the end of January of the following year, the stations started arriving at the plant. Together with BMG3-CN, we immediately started the station installation and commissioning. We completed the installation for 63 stations in only 9 days, and all processes were released within 25 days. The first battery pack was assembled and tested on March 19. I clearly remember April 9—it was the day we officially start production. We accomplished this within six months, from the project start in October to start production in April. During this time, our customer also made several site visits and audits, and they expressed high praise for our efforts. On May 15, our battery packs passed all the product verification tests required by the customer, allowing us to officially start delivery.

During the station installation and commissioning phase, the team rotated in 2 shifts working day and night to ensure the project can be completed on schedule. The efficient teamwork enables us to complete the task successfully. The project phase includes traditional Chinese holiday, Spring Festival, and the entire team were fully prepared to do overtime during the holiday. We started back at work on the third day of the Chinese New Year. I would like to express my gratitude to our team members and their families for their understanding, support, and contributions, which helped transform this challenging period into many fulfilling moments. Following start of production on our line, we gained significant acclaim from Germany, and we got multiple visits from their team, to learn about our production line and our managerial experience.

During the project implementation, we carried out multiple technical innovations and improvements. For example, in the key process green laser welding for flexible foil, the first production line in Eisenach plant had a scrap rate of around 5% during that time. One of the main reasons is the gap between flexible foil and PCB during welding. Our local process, engineering, quality, and production teams brainstormed solutions, and improved the station design to change the fixation of flexible foil from indirect to direct contact. Ultimately, our scrap rate is below 0.3%.

The first production line in Eisenach plant is fully automated and quite complex, and all the stations are connected to each other. If there is any stop in the upstream, it will impact the downstream, leading to lower OEE of the entire line. To improve the machine utilization, we reduced the automation rate in the initial design phase of the production line, changing some automation steps to manual steps. As an example, for the flexible foil assembly, we define the loading concept as manual to avoid the frequent downtime of robot caused by the slight deformation of flexible foil. We also defined decoupling point between the line, so that downstream can keep operating even if there is a problem with the upstream. The results were highly satisfactory. Within 8 weeks from SOP, we met our ramp-up targets, achieving OEE of 87% and IDC 1.7%. Currently, the OEE is already stabilized at 95%, and IDC below 0.3%. Going forward, we will continue to optimize our production processes to improve efficiency and minimize failures.

The project's success would not have been possible without the strong support from management and the close collaboration of team members. During the project, the management provided us with great trust and support by supplying sufficient resources and getting personally involved in important milestones. From the start of commissioning of stations, until the successful ramp-up, our technical plant manager joined our morning meeting every day to review the performance and progress from the day before and providing guidance and resource support. In the early stages of the project, our team traveled to Germany to learn about the product and production processes. Eisenach plant also sent technical experts to support our commissioning activities. This cross-border collaboration not only raised the project's chances of success but also fostered trust and synergy between the teams.

Reflecting on the entire project now, I realize that Bosch's corporate culture and team atmosphere played a crucial role in such a high-pressure work environment. We upheld the values of "Fight for change, Mission guarantee" and everyone on the team gave their all. The confidence we had in facing challenges was enhanced by the trust and support from management. Mutual trust between team members and collaborative problem-solving across departments are vital for the success of the project. The success of this project not only boosted the team's confidence but also laid a foundation of valuable experience for future projects. I believe that this formidable team is a product of Bosch's long-standing commitment to a culture of long-term thinking, and it will, in turn, further nurture our values at Bosch.