FMECA for Energy Storage: Value-Added Maintenance

Nexus Global partnered with the largest producer of solar energy storage systems to develop FMECA and deploy value-added maintenance strategies for a new product generation. Using Strategy Optimizer™, risk-based tasks were standardized and rapidly rolled out across like assets—improving reliability and time-to-value.

Why FMECA Matters for Battery Energy Storage (BESS)

Launching a new energy-storage generation requires structured risk analysis (FMECA) and deployable maintenance strategies across cells, modules, packs, PCS/BMS, and cooling—so availability and safety scale with production.

Engagement Scope

Build System/Component FMECAs (Cells → Packs → PCS/BMS → Cooling)

• Severity, occurrence, detectability scoring

• Focus on BMS/thermal management and interconnects

Convert Critical Modes to Tasks

• Value-added tasks: inspections, condition-based checks, redesign triggers

• Intervals and triggers tied to risk and operating context

Rapid Deployment with Strategy Optimizer™

• Template, version, and deploy strategies to like assets

• Maintain governance with change logs and approvals

Results & Expected Impact

Clearer maintenance rationale, faster strategy roll-out, improved reliability and safety posture, and better warranty decision-making via standardized closeout data.

“It’s exciting to be at the forefront of a client’s new product release and to finally work with an OEM (Original Equipment Manufacturer) that wants to provide the best strategy portfolio to a client. As opposed to a book of OEM recommendations that carry a high cost for the clients to execute and no alignment to failure modes,” explains Nexus Global CEO/President Larry Olson. “I believe the end-users of this product will really appreciate the extra effort this company has put into product care to assure reliability, as well I am positive the warranty claims will be low, which leads to a win/win.”

Lessons for OEMs & Integrators

• Treat BMS/thermal modes as top-of-stack risk

• Keep code sets and task libraries short, curated, and owned

• Close the loop: feed field findings back into FMECA and task intervals quarterly