Application of Multivariate Analysis to Increase the Yield of Dry Cell Batteries

In an organization, the manufacturing process of a dry cell battery was suffering from the problem of frequent stoppages in the assembly line. The complete battery manufacturing operation is highly automated and mechanized. It was suspected that excessive variation in overall height of bobbin was the major reason for such stoppages. The bobbin, the inside part of a dry cell battery acting as cathode, is formed by the battery extrusion process. A planned experiment was carried out on the extrusion process that identified the setting of extrusion machines and the amount of water content in the cathode mixture as the parameters causing variation in the bobbin characteristics. The problem of frequent stoppages was eliminated when appropriate action was taken on these two parameters. Finally, multivariate and univariate control schemes were developed for online control of the bobbin characteristics.