A lean-based approach for specialized lithium-ion battery packaging in automotive prototype development: a case study

Purpose The rapid expansion of the electric vehicle sector has highlighted the significance of lithium-ion batteries (LIBs) and the need for specialized packaging. However, there exists a research gap in managing specialized packaging for LIBs during prototyping processes. This research, in a case study, aims to fill that gap by examining the challenges associated with specialized packaging in the automotive prototype context. Design/methodology/approach After selection of our case company, its data were gathered using three rounds of expert input. The analysis then divides the identified specialized packaging challenges into categories; then Multi-Criteria Decision-Making (MCDM) is used to identify best-match lean tools for dealing with the categories. Findings Analysis of the interview data collected revealed 24 challenges related to specialized packaging, which were categorized into 4 distinct themes. Through analysis of the focus group discussion, 13 challenges were identified within the 4 themes, as applicable to LIB-specialized packaging and subsequently formed the foundation of the survey. Furthermore, the application of multi-criteria decision-making to the survey data enabled the identification of lean tools appropriate for addressing the four identified themes of challenges. Originality/value This paper contributed to the establishment of a structured method to facilitate the implementation of lean tools in the management of specialized packaging within the case of an automotive prototyping process.