<p>The growing adoption of electric vehicles leads to an increasing volume of end-of-life battery systems, posing significant sustainability and recycling challenges. Manual disassembly remains standard practice, but the diversity and complexity of electric vehicles battery system designs make the process labor-intensive, expensive and difficult to scale. Automation offers promising solutions, yet technological and procedural barriers remain. Lean management principles, focused on standardization, efficiency, and continuous improvement, can help overcome these challenges. This study presents a systematic literature review analyzing how lean methods are currently applied in the disassembly of electric vehicles battery systems. Findings show that lean approaches are frequently used to improve subprocess efficiency, reduce costs and processing time, and enhance sustainability. However, most research addresses isolated aspects, lacking an integrated, structured framework. Key gaps include the combination of lean with automation technologies, knowledge transfer into industrial practice, and comparative evaluation of different solutions using continuous improvement cycles. This study provides a comprehensive overview of current research and offers recommendations for developing efficient, scalable, and sustainable disassembly processes. It highlights the critical role of lean thinking in realizing a circular economy for electric vehicle battery systems through reuse and resource recovery.</p>

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Towards recycling excellence: a systematic review of applied lean methods within the disassembly of electric vehicle battery systems

  • Gerald Bräunig,
  • Dominik Hertel,
  • Matthias Thürer

摘要

The growing adoption of electric vehicles leads to an increasing volume of end-of-life battery systems, posing significant sustainability and recycling challenges. Manual disassembly remains standard practice, but the diversity and complexity of electric vehicles battery system designs make the process labor-intensive, expensive and difficult to scale. Automation offers promising solutions, yet technological and procedural barriers remain. Lean management principles, focused on standardization, efficiency, and continuous improvement, can help overcome these challenges. This study presents a systematic literature review analyzing how lean methods are currently applied in the disassembly of electric vehicles battery systems. Findings show that lean approaches are frequently used to improve subprocess efficiency, reduce costs and processing time, and enhance sustainability. However, most research addresses isolated aspects, lacking an integrated, structured framework. Key gaps include the combination of lean with automation technologies, knowledge transfer into industrial practice, and comparative evaluation of different solutions using continuous improvement cycles. This study provides a comprehensive overview of current research and offers recommendations for developing efficient, scalable, and sustainable disassembly processes. It highlights the critical role of lean thinking in realizing a circular economy for electric vehicle battery systems through reuse and resource recovery.