Results at a Glance
Improved mission readiness through capacity-based battery management.
38% longer runtime
Average measured radio battery runtime increased from 7.6 to 10.5 hours.
82% fewer field failures
Reported battery-related radio failures fell from 17 per quarter to 3.
1,240 batteries managed
Battery condition and service history were tracked across four locations.
21% lower replacement costs
Condition-based decisions reduced unnecessary battery replacements.
Customer and Challenge
A Fully Charged Battery Was Not Always Mission Ready
A North American defence organization managed 1,240 rechargeable radio batteries across four locations, supporting training, base operations and field deployments lasting eight to ten hours.
Although fully charged, some batteries no longer provided enough runtime. An internal review found that 19% of the fleet failed to meet the eight-hour requirement, contributing to 17 radio failures in one quarter and approximately 180 replacements each year.
The organization needed a consistent way to:
• Identify weak batteries before deployment
• Confirm whether each battery could support the full mission
• Standardize readiness decisions across locations
• Reduce unnecessary battery replacements
Solution and Workflow
Managing Batteries as a Fleet
The organization introduced Cadex battery analyzers and centralized battery records to measure capacity before batteries entered mission-ready inventory.
Each battery followed a consistent five-step process:
Identify → Test → Classify → Stage → Monitor
• 80% capacity or greater: Field deployment
• 70% to 79%: Training or non-critical use
• Below 70%: Recondition or replace
Impact
Greater Confidence Before Deployment
Capacity-based testing helped remove weak batteries before they reached the field. Personnel received batteries that had been evaluated against a defined runtime requirement rather than charge status alone.
All four locations followed the same readiness standard, improving consistency and helping supervisors make more informed replacement decisions.
Before
7.6-hour average runtime
17 field failures per quarter
Replacement based on age or complaints
Inconsistent testing between locations
Limited battery history
180 batteries replaced annually
After
10.5 hours average runtime
3 field failures per quarter
Condition-based replacement
Standardized 80% readiness threshold
Centralized records for 1,240 batteries
142 batteries replaced annually
Improve Radio Battery Readiness
Improve Radio Battery Readiness
Cadex helps military and defence organizations measure battery condition, manage battery fleets and identify weak batteries before critical equipment is deployed.