Start-ups from outside the automotive sector are entering the automotive market more and more frequently. VinFast, a subsidiary of Vingroup, is the first high volume automotive manufacturer from Vietnam with a specific mission: to build a smart factory to produce 250,000 cars per year in the first phase, initially with conventional drives and eventually with electric drives. Dürr is currently constructing the highly automated facility in Haiphong. The paint shop will feature integrated Industrial Internet of Things (IIoT) technology in addition to an innovative building design that reduces costs and requires less space than conventional facilities.
VinFast is a start-up of the VinGroup, the largest, non-state-owned listed company in Vietnam with a market capitalization of approximately VND 340 trillion (USD 14.6 billion) as of July 31, 2018. Vingroup’s strategy is to become the leading technology – industry company in Vietnam and the region. The VinFast brand is the Group’s first foray into the mobility market, and offers enormous growth potential due to the robust demand for vehicles in Southeast Asia.
VinFast intends to establish itself by manufacturing automobiles delivering best-in-class quality produced in a factory equipped with state-of-the-art technology that enables transparent, lean processes. In order to achieve this ambitious investment objective in the paint shop, VinFast commissioned Dürr to handle this project.
“Our paint shop will be the biggest in Vietnam, and highly automated through the integration of numerous IIoT applications. This makes it the benchmark for outstanding quality combined with the best operating costs, the highest ecological standards, and a high level of occupational safety,” explains James Deluca, CEO of VinFast Trading and Production Company.
Patented layout concept for a lean building
VinGroup constructed the building for the paint shop based on the patented layout concept developed by Dürr in less than eight months. The layout minimizes the investment and operating costs by using only two levels and eliminating the so-called “penthouse” level used by other paint shop configurations. The compact design reduced the concrete area by approx. 15,000 m2. This corresponds to a saving of more than 20 percent compared with a conventional concept.
VinFast’s desire for maximum automation of production processes and logistics required IIoT-capable machines from end to end. They are entirely controlled, monitored, and supervised in real-time using control technology from Dürr. This makes it possible to easily test and optimize the overall equipment efficiency (OEE).
Flexible technology for future targets
The paint shop technology meets the current requirements of VinFast while remaining flexible to accommodate future changes. The EcoInCure oven achieves the best possible topcoat appearance quality due to the inside out heating process and optimized airflow. Each body gets a digital quality certificate for the drying process. The IIoT-capable oven collects and evaluates the data. In addition, EcoInCure’s space-saving, transverse mode of operation in combination with a central high-bay warehouse makes it ideal for the compact building concept.
The principle of heating from the inside is an important benefit for automotive bodies with different material thicknesses – electric vehicles with a reinforced frame on the underbody are a perfect example. The EcoInCure drying method significantly reduces thermal component stresses compared with conventional ovens. VinFast is well prepared for the eventual expansion of the model range to include electric vehicles.
The new VinFast paint shop will also be equipped with the latest generation of the fully automatic EcoPaint robot. This includes the extremely mobile painting robots with seven-axis kinematics, which do not require a rail. This saves space and investment costs. Equipped with a whole range of sensors, they are prepared for the requirements of an Industry 4.0 environment. The robots supply real-time data that is analyzed and evaluated using the latest software products from Dürr.
In addition to the EcoInCure innovations and seven-axis robots described, Dürr will also be installing further technical highlights in the VinFast paint shop:
- RoDip rotational dip process
The efficient RoDip rotational dip process will be used at VinFast throughout the PT/EC (pre-treatment and electrocoating) area. The rotational movement of the bodies does away with the need for entry and exit inclines at the immersion tank, making the tanks more compact. This reduces the unit costs because the smaller tank capacity uses less energy, less water, and fewer chemicals than other technical solutions.
- EcoDry X dry separation
EcoDry X for dry paint overspray separation is a multi-stage, easy-to-handle filter system that comprises filter trolleys with six filter boxes each and downstream pocket filters as the second filter stage. The semi-automatic separation system sets the standard for high separation capacity and low filter costs.
With all of these state-of-the-art technologies, the new paint shop for VinFast is geared towards the strategic goals of the start-up: highest quality standards at the lowest operating costs, low environmental impact, and high health protection and occupational safety with high future security.
About The Dürr Group
The Dürr Group has been established in the United States since 1970 and currently employs around 880 people. From the new Campus with a state-of-art validation, testing, and training center in Southfield, MI, Dürr USA represents four of the five divisions. Paint and Final Assembly Systems offers equipment for painting and assembly processes, while Application Technology provides paint application systems. Dürr’s Clean Technology Systems is the global leader in air pollution abatement and energy efficient technologies. The subsidiary Schenck Trebel Corporation, based in Deer Park, New York, offers balancing machines, vibration and condition monitoring systems and services for the general industry. The customers of Dürr USA include automotive and commercial vehicle manufacturers as well as their suppliers, and a diverse group of other industries. HOMAG Machinery North America operates the production facilities for HOMAG Group in Grand Rapids, MI, which is also the base for sales and service company Stiles Machinery Inc.
The Dürr Group is one of the world’s leading mechanical and plant engineering firms with extensive expertise in automation and digitization/Industry 4.0. Products, systems and services offered by the Group enable highly efficient manufacturing processes in different industries. Dürr supplies sectors like the automotive industry, mechanical engineering, chemical, pharmaceutical and woodworking industries. The company has 92 business locations in 31 countries. The Group generated sales of € 3.71 billion in 2017. Dürr has around 15,000 employees and operates in the market with five divisions:
- Paint and Final Assembly Systems: paint shops and final assembly systems for the automotive industry
- Application Technology: robot technologies for the automated application of paint, sealants and adhesives
- Clean Technology Systems: exhaust-air purification systems and energy efficiency technology
- Measuring and Process Systems: balancing equipment as well as assembly, testing and filling technology
- Woodworking Machinery and Systems: machinery and equipment for the woodworking industry