Optimize Battery Production with These 8 Modular Material Handling Structures 

The battery industry is growing at an incredible annual growth rate (CAGR) of 16.63%. However, with that growth comes numerous challenges. Constant battery design changes, the demand for more efficient, longer-lasting batteries, cost control, safety, maintaining electrostatic discharge (ESD) compliance, and the need to continually increase production mean that battery manufacturers must embrace lean, modular material handling systems. 

Meeting this challenge head-on is the steel tube and joint modular material handling system offered by Flexpipe Inc. The ultimate in scalability and flexibility, Flexpipe’s steel tube and joint system is lean personified, allowing battery manufacturers to design, assemble, change, and modify whatever battery handling equipment they need.

Key takeaways 

Battery production plants face rapid design changes, strict ESD requirements, and relentless pressure to scale. Flexpipe’s modular steel‑tube system lets engineers build customizable carts, racks, and workstations that re‑configure in minutes—no welding required.  

Result: faster line changeovers, safer ergonomics, and up to 50 % lower lifetime material‑handling costs.

Why Choose Modular Material Handling Structures

Conventional material handling structures are not lean and do not allow for continuous improvements. They are most often welded, with fixed dimensions. These fixed material handling structures aren’t just expensive to buy; they’re also expensive to maintain, and changing or modifying these structures is often more costly than buying new. 

Fixed, welded material handling structures offer no flexibility whatsoever. They are purchased to address a one-time material handling need. When the material handling requirements change or the production process changes, these fixed, welded structures quickly become obsolete.  

For battery manufacturers adopting lean manufacturing, using fixed welded material handling structures like welded carts, trolleys, work benches, workstations, flow racks, and shelving is a constant money drain.

Benefits of Flexpipe Steel Tube and Joints for Battery Handling Equipment

While fixed-in-place, welded structures cannot be changed or modified without incurring substantial costs and lost time, Flexpipe’s steel tube and joints can be altered, modified, or adjusted within the battery manufacturer’s facility.

With Flexpipe, battery manufacturers can design and assemble made-to-fit ESD-safe carts, trolleys, flow racks, workstations, work benches, Takt Boards, 4-panel boards, and information panels. All these material handling structures can be designed, assembled, and used anywhere along the EV battery assembly line. All can be changed and adjusted on-site.

With Flexpipe’s steel tube and joints, battery manufacturers can design ergonomic, ESD-compliant workstations and material handling structures that increase safety. As material handling requirements change, the structures can be changed accordingly.

Ultimately, Flexpipe steel tube and joints allow for the ultimate in agility, with structures easily built by battery production technicians and employees. It’s a simple lean manufacturing tool that produces incredible returns. Changes that can be done on-site with minimal downtime compared to changing welded structures.

If you’re dealing with frequent design changes and ESD requirements, download our free ebook: Lean Material Handling for Battery Manufacturers for a deeper breakdown of lean principles and structure examples.

8 Essential Modular Material Handling Structures for Battery Manufacturing

1. FIFO Flow Racks for Line-Side Component Feeding

First-in, First-Out (FIFO) flow racks are the ideal solution for providing line-side technicians and battery production employees with immediate access to material bins. Everything on a Flexpipe FIFO flow rack can be customized. From customizing the height, width, and number of racking levels to adjusting the distance between each level and accommodating different material bin sizes, everything can be made-to-fit with a Flexpipe FIFO flow rack.

Each level of a Flexpipe FIFO flow rack is angled at 15 degrees. Each level has stoppers in place to keep the material bins stationary. As each material bin is removed, the next material bin slides down and takes its place. New bins are stored behind the FIFO flow rack, ensuring a steady supply of materials to battery production employees.

Everything on a Flexpipe FIFO flow rack is made from Flexpipe materials. From the steel tubes and joints, connectors, rollers, stoppers, and casters to angle joints – all are Flexpipe building materials.

The ultimate visual management system, Flexpipe FIFO flow racks for line-side component and material handling, reduce lost time and workflow interruptions caused by material shortages.

2. Picking and Kitting Carts Delivering Materials to Workstations

Flexpipe kitting carts are the ultimate solution for delivering kitted work-order material requirements directly to various workstations and work cells. Whether needing ESD-compliant decking material to protect parts susceptible to static electricity, customized bin sizes for different materials, or simply requiring made-to-fit locations and shelving for materials, tools, and instructions, Flexpipe kitting carts can be customized to any kitting material size or requirement.

3. Tugger Carts, Trolleys, and AGV-Compatible Carts for Material Transport

The Flexpipe material system also allows for designing and assembling customized trolleys and tugger carts for manual transport or with an automated guided vehicle (AGV). Customized tugger carts are essential for efficient warehouse management and for transporting large volumes of materials to various areas of the battery production shop floor.

From thick square steel pipes for the base of the tugger cart or trolley to all the joints, casters, ESD-compliant decking material, steel pipes, industrial casters, roller tracks, and Kaizen foam, all are part of the Flexpipe material handling solution.

4. Work-in-Progress (WIP) Racks to Transport Semi-Finished Batteries

Flexpipe WIP racks and carts enable the safe and efficient transportation of heavy battery modules and casings. These WIP carts can be customized to hold semi-finished battery parts and casings in different stages of production, helping to protect the parts during transit.

With ESD-compliant decking and customized spacing, battery manufacturers can create WIP carts that securely and safely protect all surfaces of a given semi-finished battery part.

5. Ergonomic ESD-Compliant Modular Assembly Workstations for Increased Efficiency

With Flexpipe, battery manufacturers can design, assemble, change, and adjust ESD-compliant modular assembly workstations as needed. Incredibly ergonomic and sturdy, Flexpipe modular workstations can be customized to the specific battery component or casing being assembled. If the battery design changes or the workflow process changes, designs can be completed on-site with minimal downtime.

Flexpipe modular workstations improve worker efficiency, are incredibly adaptable, and provide improved safety as wires and cables can be attached to Flexpipe modular workstations with tie wraps.

6. ESD-Safe Mobile Workstations

For workflow, material flow, and assembly applications that don’t require fixed workstations, a Flexpipe mobile workstation is the best solution. Complete with ESD-compliant decking materials, these mobile workstations can be made to whatever dimensions are needed.

With industrial casters for easy maneuverability, these mobile workstations can be positioned anywhere on the battery production shop floor.

7. Heavy-Duty Battery Module Handling Carts

Large, mobile carts are the ideal solution for protecting large components and large battery modules when moving from one production workstation to another. Whether it’s creating a large mobile cart with protective foam to protect parts from damage, building a surrounding structure to protect each level of the cart, or needing a large mobile cart that is easily moved and ensures worker safety, Flexpipe’s steel tube and joint system is the ultimate solution.

8. FIFO Component Storage Shelving

With stationary FIFO flow racks, battery manufacturers have a steady supply of materials that acts as a visual inventory management solution. Much like the mobile FIFO flow racks, material bins are stored from the back of the FIFO flow rack. Each level is angled at 15 degrees and has a stopper to keep the material bins in place.

As each bin is withdrawn, another bin slides down the Flexpipe roller tracks and is held in place with stoppers. With stationary FIFO flow racks, visual inventory management is optimized, and inventory obsolescence dramatically decreases.

Real-World Benefits of Modular Structures in Battery Manufacturing

As a material handling solution, the Flexpipe steel tube and joint system addresses all the core industry challenges faced by today’s battery manufacturers.

• Rapid product changes
• Scalability and growth
• Safety and ergonomics
• ESD compliance
• Quick implementation
• Low-cost reconfiguration

Getting Started: Choosing the Right Modular Solution

Here is a list of essential criteria all battery manufacturers should consider when selecting what type of modular material handling structure they will build with Flexpipe.

• Balance Current and Future Needs: The Flexpipe material handling system allows battery manufacturers to change their structures as needed. If you envision a given production line expanding, then focus on a design that allows for increased scalability.

• Evaluating safety and Compliance Requirements: Battery manufacturers need ESD-compliant decking materials. Flexpipe provides numerous ESD-compliant materials to ensure battery manufacturers can assemble an ESD-safe material handling solution.

• Consider Ergonomics and Workflow: Always remain vigilant about the need to design and assemble material handling structures that are ergonomically friendly and always safe for use. Also consider workflow and future changes to that workflow.

Flexpipe Material Handling Solution: The Ultimate Benefit for Lean Battery Manufacturers

The Flexpipe material handling solution is the best option for battery manufacturers in lean environments. The steel tubes and joint system are incredibly durable, strong, robust, and low-cost. Changes require minimal downtime and can be made as needed.

In a lean environment where continuous improvement is the guiding principle, Flexpipe’s steel tube and joint system ensures that lean best practices thrive.