Video: Up to 90 percent of battery manufacturing data is wasted and Siemens plans to change that – Charged EVs

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Video: Up to 90 percent of battery manufacturing data is wasted and Siemens plans to change that – Charged EVs


As EV battery manufacturing ramps up worldwide, Siemens is working to address critical data challenges through a digital transformation. Charged recently chatted with Puneet Sinha—Senior Director, Global Head of Battery Industry at Siemens Digital Industries Software—to learn how it’s bringing a new level of precision and efficiency to the process.

Traditional battery manufacturing is often experience-driven, which can lead to inconsistencies in quality. Sinha explained that Siemens is working to make manufacturing more standardized and reliable by leveraging data that is typically underused, as up to 90% of factory data is often wasted. Their goal is to contextualize this data, turning it into actionable insights that reduce scrap rates and improve quality.

A central part of Siemens’ approach is its use of digital twin technology. With digital twins, companies can model and test new battery designs virtually before committing to physical prototyping. This reduces time and costs, helping manufacturers evaluate concepts digitally to optimize designs before production. The digital twin also supports the scale-up process from lab to full-scale production, addressing challenges in going from a pilot to a “Giga scale.”

Siemens is also actively supporting the battery ecosystem in the United States, helping companies innovate and scale quickly to meet growing demand. Their technology supports advancements in various battery types, including solid-state and sodium-ion batteries. By providing tools that integrate multiple engineering domains—such as chemistry, mechanical, electronics, and software—the company is helping manufacturers manage complex trade-offs early in the development cycle. The goal of this approach is to enable faster innovation and help companies meet cost and quality standards crucial for competing in the EV market.

Battery Passport Mandates
Looking ahead, Siemens is preparing companies for future regulations like the EU’s battery passport mandate, set to go into effect in 2027. This regulation will require extensive traceability for batteries, ensuring transparency across the supply chain. Siemens offers a secure, cloud-based battery passport platform that helps manufacturers comply with these regulations. By managing data from manufacturing to end-of-life, the battery passport meets regulatory requirements and provides valuable insights for optimizing battery usage and lifespan. Through a combination of data intelligence, digital twins, and automation, Siemens plans to shape a more efficient, sustainable future for battery production.



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