Abstract Consistent and optimum formation is critical to performance and durability of lead/acid batteries. Delco Remy's approach to formation consistency includes conformance to process, material and product requirements, and the accommodation of model mix variables in the plant. An overall process model for formation control is presented. Specially designed charge tables, air-moving equipment, and optimized procedures are utilized to achieve control of formation results. The influence of battery design variables on optimum current schedules is reviewed. Use of computer-generated schedules for coordination of process and design factors to achieve predictable and consistent product characteristics is suggested.