FMECA in Energy Storage Tech Brings Value-Added Maintenance Strategies

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.

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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

 Download the Strategy Optimizer™ Brochure

FAQ

Why use FMECA for energy storage?
It prioritizes failure modes (cells, packs, BMS, cooling) and links them to targeted tasks that prevent or detect issues early.

How does Strategy Optimizer™ help?
It templates FMECA-derived tasks, versions strategies, and deploys to like assets—cutting time to value while tightening governance.

What outcomes should OEMs expect?
Standardized maintenance logic, faster roll-out, clearer warranty data, and improved reliability/safety posture.

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