DutchBoy ENERGY · Battery & Solar Manufacturing
Down to every weld and every cell — connecting process conditions and quality in energy manufacturing
DutchBoy ENERGY unifies equipment conditions, weld waveforms, inspection images and measurement data from battery and solar processes into a single time series. It finds which process, equipment and condition a defect started from, and tells you what to inspect first.
Applicable Processes
Data Analyzed
Pulse
Equipment conditions · power · pressure · temperature
Wave
Weld waveforms · continuous process signals
Vision
Vision · EL inspection images
Table
Measurements · charge/discharge · MES quality
What existing systems tell you — what happened. What's still up to people — why, and what's next.
Defects show up only in the results
Weld and bonding defects surface only in visual or pull tests or downstream measurements, and are hard to tie back to the conditions that caused them.
Conditions and results live apart
Equipment PLC/HMI, weld monitors, vision/EL inspectors and MES quality data are each stored separately.
Fixed limits fall short
When the model, recipe or material lot changes, alarms fire falsely or anomalies within limits go unnoticed.
Inspection depends on who's on shift
There's no record of which checks actually worked for recurring defects.
The data you already have, read as one — anomalies, root causes and actions, delivered.
Input · existing systems and data
DUTCHBOY ANALYSIS
Collect & clean
Align scattered data on one timeline
Detect anomalies
Score deviations from the normal baseline
Find root causes
Where, what and why it differed
Connect to action
Next steps backed by past cases and evidence
Sensor, waveform, measurement and image data are all converted to time-series and analyzed by one engine — no need to build a new model for each data type.
Output
- Anomaly scores and out-of-range alerts by process and equipment segment
- Suspect welds and bonds flagged from waveform patterns
- Inspection defects linked to process conditions on one timeline
- Side-by-side comparison of equipment, lines and zones at the same moment
- Inspection priorities based on how well past actions worked
- Automatic model retraining and version management
Your existing systems, unchanged — just the 'why' and 'what next' added on top.
Weld monitors · equipment HMI
Limitation
Fixed upper and lower limits on individual signals such as current and power
What DutchBoy Adds
Compares multiple signals and waveform shapes together against a normal baseline, accounting for recipe changes and stoppages
Vision · EL inspectors
Limitation
Judge defects, but separately from process conditions
What DutchBoy Adds
Ties defects to equipment, segment and time so they can be compared with process conditions on the same axis
MES · QMS
Limitation
After-the-fact totals by shift or day
What DutchBoy Adds
Links defect trends and condition drift in real time while the process runs
Maintenance logs
Limitation
Inspection results scattered as free text
What DutchBoy Adds
Accumulates actions and their effectiveness to recommend what to check next
External analytics models
Limitation
Must be rebuilt whenever the data changes
What DutchBoy Adds
Keeps models running with automatic retraining, validation and versioning
One approach, different problems — solved in every process.
Laser and ultrasonic weld quality for tabs and busbars
- 1Collect weld waveforms, power and pressure
- 2Flag welds that deviate from normal patterns
- 3Check contributing signals and equipment conditions
- 4Isolate suspect cells and modules · inspect
Electrode process condition anomalies
- 1Link coating and drying conditions to thickness and density measurements
- 2Detect abnormal segments and zones
- 3Identify the affected lots
- 4Verify after adjusting conditions
Root causes of interconnection and inspection defects
- 1Link heating and soldering conditions to EL and vision defects
- 2Pinpoint the abnormal equipment, zone and main cause
- 3Rank checks by past fixes
- 4Record the outcome of each action
Only the modules you need, added on top of what you have — Core to start, automated reporting and conversational AI as Add-ons. Every module running on the plant data Weave designs.
Your existing systems — unchanged
Weave
Data designCollects data from equipment, welders, inspectors and MES, connects remote plants and tracks collection gaps
Sense
Detection & RCADetects anomalies in process conditions and weld waveforms, links defects to conditions, retrains automatically
Recall
Recall & responseRecommends inspection priorities from defect-type checklists and past fixes
Watch
Integration & alarmsShows equipment alarms, recipe changes, stoppages and inspection throughput together
Visualize
Evidence & reportingProcess and inspection evidence charts, shift and daily reports
Agent
Query & reasoning'Why did weld defects rise on Line 2?' → answers with evidence and an inspection order
Why an LLM alone isn't enough — Time series from just 150 sensors add up to millions of numbers (about 5.4 million in our technology video example), far more than an LLM can read directly. DutchBoy's manufacturing-specific tools condense them into a few lines of key evidence — severity, pattern, scope of impact and past cases — and hand them to the Agent.
Could this fit your process?
From feasibility to expected impact, the AIBIZ team will walk you through it directly.