Mapping the cause of high warranty claims in a battery manufacturing company revealed that major cause is loose welding of battery terminals. Setting a quality control procedure, training the staff, and maintaining the welding machines and tips reduces those claims, and consequent market returns.

The hardening process was identified as the main cause of battery defects, leading to market returns. Review of the operating conditions during the hardening process, including proper stacking of trays, monitoring of humidity, and curing procedures positively improve the hardening process and reduce the product returns.