From first requirement to production, one platform.
EstesOS runs Estes from a customer’s first requirement to the pack that ships. Requirements, designs, tests, parts and build steps share one AI-enabled record, and a live digital twin shows the whole factory as it runs.
We build the factory and the software that runs it.
Battery programs are won or lost in production, so we built our factory and its software as one system.
Traceability
Every cell traced, from the clause in your spec to the pack it ships in.
AI across one record
The lab, the supply chain and the line share one record, and AI follows a thread through all of it, showing its sources.
A live digital twin
The whole floor mirrored live, so every station, rack and lot is visible the moment it changes.
PLM, ERP, MES and QMS, in one record.
Most manufacturers run four systems from four vendors and reconcile them by hand. EstesOS is one, so a change anywhere reaches everywhere the same day.
LabOS: requirements, design and validation
Every requirement, verified by test.
Requirements management starts at your specification: AI reads it clause by clause and breaks each requirement down from system to pack, module and cell. Every level has its test on the other side of the V, and each result rolls back up as evidence, so “why does this meet spec?” is answered all the way down to the cell.
- Your requirementverified byAcceptance
- Systemverified bySystem validation
- Packverified byPack test
- Moduleverified byModule test
- Cellverified byCell test
One BOM, every revision.
EstesOS’s PLM keeps every part, revision and CAD file in one bill of materials, with mass and cost rolled up live against target. Release a revision, and the lab’s test plan and the line’s work instructions follow it.
- PN 410-0128 · LidRev C · 4.1 kg
- PN 430-0107 · BusbarsRev D · 2.4 kg
- PN 420-0311 · ModuleRev E · 31.6 kgReleased
- PN 450-0088 · BMSRev D · 0.9 kg
- PN 410-0130 · End coverRev B · 1.2 kg
- PN 410-0129 · TrayRev C · 5.8 kg
- Pack rollup · Rev E98.4 kg of 100 kg targetOn target
Every test on record, so every iteration is faster.
Our LIMS gives every cell that enters the lab a record of its own, and every test channel reports in around the clock. Each new design is measured against everything we’ve tested before, so we know early whether it’s better, and the next revision goes on test sooner.
- 2,300+ cells tested, each with its full history
- 300M+ measurements in one record
- 15 s between readings on every channel, day and night
- Chamber TC-0325.0 °C · set 25.0 °C
- EC-02317 · Ch 213-2SOH-E 96.4% · 15 s agoIn Testing
One plan, from lab to line.
Requirements, design revisions, lab capacity and line capacity are scheduled together. When a test runs long, every date that depends on it moves with it.
ManufacturingOS: supply chain, manufacturing and quality
Release a revision. The line builds it.
A BOM released in PLM becomes the process our MES runs: every step, tool, part and limit. Engineering changes reach the stations they affect, each unit records the revision it was built to, and nobody builds to an old drawing.
EstesOSBOM · Magnus packRev E- Pack
PN 400-0001 - Module×8
PN 420-0311 - Cells×52
PN 300-0021 - Busbars×4
PN 430-0107 - BMS×1
PN 450-0088 - Enclosure×1
PN 410-0127
EstesOSProcess · Line 1Rev E- 1Cell inspectionHioki BT4560 · voltage and resistance
- 2StackingFixture F-12 · 52 cells
- 3Module assemblyBusbar weld · torque 12.0 N·m
- 4End-of-line testHypot tester · Neware cycler
Station 3 · Module assemblyRev EWeld busbar 4 of 8 on module M-04.
- Unit
- M-04 · built to Rev E
- Weld energy
- 41.8 J · limit 38–46
- Operator
- OP-0142 · 14:02:17
Every part, traced to its lot.
Our ERP runs suppliers, purchase orders, receiving and inventory in the same record as the BOM. Every lot follows its parts into the build, and the line knows it’s clear to build before a shift starts.
Wired to every tool, checked at every step.
Our MES guides every step on the operator’s screen. Cyclers, testers, torque tools and scanners write straight into the record, a reading outside its limits stops the step, and every action is logged with who, where and when.
- Step 6 · Torque12.0 N·m · limit 11.5–12.5Pass
- Operator · Station 314:02:17 · step logged
Quality caught at the step, not at the customer.
Incoming inspection, holds, nonconformances and corrective actions run through our QMS, in the same record as every test and build. When a lot is suspect, it’s held across the lab and the line in minutes.
The whole factory, live.
Every station, rack and channel reports into a live digital twin of the floor, so a problem shows up where it happens, while it happens. And every new line starts from everything the last one learned.
AI finds the connections across all of it.
With every requirement, test, part and build step in one record, AI can follow a thread through all of it: from a clause in your spec to the cells that prove it, the lot they came from and the line that built them. Every answer shows its sources.
Ask EstesOSWhy did EC-02317 fade early?
It shares supplier lot L-118 with 11 other cells. All 12 read 8% higher resistance at incoming inspection, and the line held the rest of the lot on 14 Sep.
L-118INS-0877T-0412M-04 v14Everything moves faster when it’s one system.
Faster delivery
Lab findings reach the line without a handoff, so new designs get to production sooner.
Faster partnerships
We answer your requirements with evidence from the start, so a program begins on facts, without rounds of documents.
Faster response
If an issue comes up, we trace it to the cells, tests and build steps involved, and answer with data.
Faster scale-up
A new line starts from the last one’s process, limits and data, so capacity grows without starting over.
