BRUNIMIND Turnkey Conformal Coating Production Line_ Helping a Taiwanese Enterprise in Vietnam Break Through New Energy Vehicle Electronics Production Bottlenecks

BRUNIMIND Turnkey Conformal Coating Production Line: Helping a Taiwanese Enterprise in Vietnam Break Through New Energy Vehicle Electronics Production Bottlenecks

A factory located in Vietnam — affiliated to a Taiwanese enterprise and focusing on the R&D and production of new energy vehicle electronic products — is standing at a crossroads of development. The factory mainly manufactures large quantities of power supply boards and battery interconnection modules, which, as core components of electric vehicle systems, directly determine the stability of the entire vehicle’s operation. With the continuous growth of global new energy vehicle demand and increasingly strict tolerance for product defects, the factory’s original coating process has gradually failed to keep up with the needs of capacity upgrading and quality control, becoming a core bottleneck restricting its development.

Against this background, BRUNIMIND, a professional supplier in the PCB/SMT line equipment field, stood out and was selected to provide a turnkey conformal coating production line. This production line is specially equipped with a "return" conveyor loop, whose core purpose is to maximize operator efficiency and simultaneously expand the overall capacity of the production line, accurately addressing the customer’s urgent pain points.

Challenges: Low Process Efficiency and Rising Quality Risks

The customer’s previous coating scheme had obvious shortcomings: operators had to first load the boards to the front end of the production line, then walk around to the unloading end to pick up the parts after spraying. This round-trip not only wasted time and labor but also increased unnecessary production idle time, seriously reducing operational efficiency.

Without the support of an online return conveyor, the frequency of material handling and invalid operator movements increased significantly. This not only prolonged the production cycle of a single batch but also intensified fluctuations in the production process, making it difficult to achieve standardized mass production.

Given that the products are mainly used in the automotive electronics field, reliability is an uncompromising core requirement — coating defects such as missing coating, uneven coverage, and inconsistent curing may all lead to product failures in actual use, directly affecting customer reputation and market competitiveness.

In addition, the customer faced three core demands: the production line needed to be quickly commissioned and put into mass production; the equipment needed to be fully integrated into the existing MES system; and a standardized operation process suitable for multi-shift production needed to be established to ensure consistent production quality across different shifts.

Solution: A Complete Set of Online Coating Production Line with Return Conveyor

BRUNIMIND tailored a solution to address the customer’s pain points. This online coating production line was designed and installed on-site in April 2024. Throughout the project, a person in charge from the customer’s side coordinated the work, while Andrew, an experienced engineer from BRUNIMIND, took the lead in equipment installation, commissioning, and operation/maintenance training for the customer’s team. The specific solution includes the following core components and services:

Implementation Highlights

After arriving at the Vietnamese factory, Andrew first drew a detailed equipment layout plan based on the actual workshop layout. In strict accordance with BRUNIMIND’s equipment integration standards, he completed the installation and precise calibration of each piece of equipment, then conducted multiple rounds of equipment trial operation to confirm that all sensors, valves, and I/O signals met the preset specifications. He also optimized the equipment layout to further improve workshop space utilization and ensure the smooth operation of the production line.

After the equipment commissioning met the standards, BRUNIMIND tailored a comprehensive training plan for the customer. The customer’s engineering team participated in practical operation courses throughout the process, with core training content including:

•       In-depth understanding of the mechanical and electrical structure of the BRUNIMIND coater, as well as proficient mastery of the working principles of core components and common troubleshooting methods;

•       Proficient operation of the BRUNIMIND exclusive software menu, accurate setting of system parameters, efficient management of the AOI detection interface, and quick mastery of the intelligent operation process;

•       Mastery of daily equipment maintenance skills, including nozzle cleaning, valve monitoring, and curing oven conveyor belt inspection, effectively reducing equipment failure rates and extending equipment service life.

Among these, the return conveyor loop has become a key highlight in improving production efficiency: operators no longer need to rush between different workstations, but only need to load and unload goods at the same position. This greatly reduces non-value-added time in each production cycle, gives full play to the integration advantages of the BRUNIMIND production line, and achieves maximum efficiency.

After the training, BRUNIMIND conducted a strict qualification assessment for the customer’s operators. Those who passed the assessment gained the ability to independently manage the production line with sufficient operational confidence. Subsequently, BRUNIMIND continuously provides remote technical support and regular on-site maintenance services, relying on a professional service team to fully ensure the stable and efficient operation of the production line.

Results: Improved Quality, Throughput and Return on Investment

Significant reduction in defect rates: With the support of immediate post-coating AOI detection and optimized process control by BRUNIMIND, the product defect rate is estimated to have decreased by 30% compared with the customer’s previous manual and semi-manual coating processes (data based on the customer’s internal KPI statistics). At the same time, it effectively reduces paint waste, further lowers production costs, and achieves dual optimization of quality and cost.

Substantial improvement in production throughput: The scientific design of the return conveyor, combined with the efficient operational performance of BRUNIMIND equipment, effectively reduces invalid operator movements and production cycle time, increasing the number of boards processed per shift by approximately 20%. Capacity expansion is achieved without additional labor input, greatly improving production efficiency.

Significant enhancement of operational resilience: Relying on the local engineering team certified by BRUNIMIND and comprehensive training support, the customer no longer relies on frequent overseas service visits. This greatly shortens fault troubleshooting time, reduces production line downtime losses, and further improves the operational stability and risk resistance of the production line.

Continuous improvement of market competitiveness: By deploying BRUNIMIND’s advanced online coating production line, the customer can better meet the strict standards in the automotive electronics field (such as stability requirements under extreme temperatures, vibration, and humidity) and quickly respond to new OEM project needs, further consolidating its market position and improving core competitiveness.

Why This Approach Works

BRUNIMIND integrates the three core processes — spraying, AOI detection, and IR curing — into a single online unit. This effectively ensures process continuity, minimizes handover links of circuit boards between processes, reduces the risk of secondary damage to boards, and guarantees product quality from the source.

The design of the return conveyor loop accurately addresses the pain point of invalid operator movements, minimizes time waste, improves the production line’s uptime, and perfectly aligns with BRUNIMIND’s core design concept of "people-oriented, efficient production".

The combination of training and qualification certification is an important part of BRUNIMIND’s service system. It not only effectively enhances the operational and maintenance capabilities of the customer’s team and reduces dependence on external services but also helps the customer establish a sound internal technical team to achieve long-term stable and efficient operation of the production line.

The in-depth integration of the MES system helps the customer meet Industry 4.0 requirements, enabling traceable production processes, real-time data collection, and accurate process analysis. This demonstrates BRUNIMIND’s strong technical strength in the field of intelligent manufacturing and helps the customer achieve digital and intelligent production upgrading.

What This Means for You

If your production environment is facing any of these pressures — frequent manual board handling, high coating defect rates, disconnection between the detection area and production area, or low operator efficiency — then BRUNIMIND’s turnkey online coating solution equipped with a return conveyor may be the ideal choice to help you break through bottlenecks. Choosing BRUNIMIND’s optimized and integrated production line, rather than assembling scattered equipment, not only reduces the complexity of the production process but also improves output and quality, achieving a higher return on investment. Meanwhile, relying on BRUNIMIND’s professional technical support and comprehensive service guarantees, it helps your enterprise achieve long-term stable development and seize opportunities in the fierce market competition.