In dip coating processes, forming a functional thin film on the substrate is critical. However, the quality is extremely sensitive to slight process variations such as liquid temperature, humidity, immersion time, and withdrawal speed. As a result, the process still relies heavily on the experience and intuition of skilled operators, leading to issues such as variation in quality and difficulty in transferring expertise.
To eliminate dependence on individual skills and achieve consistently stable quality, it is essential to precisely understand what is happening in the process and manage all conditions in a centralized manner.
The key to solving this challenge is data-driven process management integrated with a Manufacturing Execution System (MES).
MES Integration: Benefits for Dip Coating Processes
Process Visualization and Real-Time Data Collection
The first step in MES integration is to fully visualize the manufacturing process.
Data from dip coating equipment and sensors is automatically transmitted to the MES via the network. This includes operating data from PLCs and measurements such as liquid temperature and humidity.
Standard industrial communication protocols such as OPC UA are commonly used for this data exchange, enabling smooth connectivity even between equipment from different manufacturers. By eliminating manual recording, this approach removes human errors such as missing entries, recording mistakes, and delayed inputs.
As a result, digital records are created with precise, real-time information, including:
- Lot number
- Exact processing time (hh:mm:ss)
- Equipment used
- Process parameters (e.g., withdrawal speed XX mm/s, liquid temperature XX °C)
Any slight deviation from preset parameters can be detected immediately and trigger an alert, allowing issues to be prevented beforehand or their impact minimized.
Ensuring Reliable Lot and Product Traceability
Process data collected automatically is accurately linked to each product’s manufacturing lot number. This enables the creation of a detailed manufacturing history, referred to as “product genealogy,” covering not only material lot numbers, manufacturing date and time, and operator, but also all process parameters and inspection results.
This traceability system proves highly effective in the event of a quality issue in the market. It allows specific manufacturing conditions to be traced back quickly and accurately, making it possible to limit the impact range and directly reduce recall risk. Furthermore, it reinforces compliance with stringent quality control standards required in industries such as automotive and medical devices, establishing a strong foundation for enhanced corporate reliability and competitiveness.
Advanced Data Management through Process Data Analysis and Utilization
Integrated Analysis of Process and Quality Data
The large volume of process data accumulated in the MES is a valuable asset on its own. By integrating this data with quality inspection results such as film thickness, uniformity, and adhesion strength and analyzing it using statistical methods or machine learning, engineers can uncover insights that were previously difficult to identify.
For example, using Statistical Process Control (SPC), complex correlations such as which parameter combinations have the greatest impact on quality can be clarified quantitatively. This enables the derivation of optimal operating conditions based on scientific evidence rather than empirical knowledge, leading to improved quality stability and higher yield.
It is an important step towards transforming the manufacturing process from a black-box state into a logically controllable system.
Data-Driven Condition Setting and Automatic Feedback
The insights obtained from integrated analysis only generate value when applied to process control on the production floor. For instance, external disturbances such as liquid viscosity or ambient temperature are detected in real time by sensors and control systems, and this information is collected and analyzed by the MES.
Based on the analysis of accumulated data, the MES can suggest or update optimal operating conditions, such as withdrawal speed, and send target values to PLCs or control systems. By implementing hierarchical feedback control between the MES and equipment, stable quality and standardized operating conditions can be achieved without excessive reliance on experienced operators.
This helps suppress quality variability, reduce operator workload, and shift work toward higher value-added tasks.
Equipment Condition Monitoring and Deployment of Predictive Maintenance
Advanced data management extends beyond product quality to equipment itself. Alongside process data, the MES continuously monitors equipment operating data such as motor current, pump pressure, and vibration. By analyzing these values over time, even slight deviations from normal conditions can be detected as signs of potential failure.
This is the basis of predictive maintenance (PdM). By predicting optimal replacement timing for wear components and identifying maintenance needs in advance, unexpected line stoppages due to equipment failure can be prevented. As a result, equipment utilization rate is maximized, supporting adherence to production schedules and significantly contributing to higher overall productivity.
Summary
Data management in dip coating through integration with a Manufacturing Execution System (MES) goes beyond simple digitization. It provides a powerful solution to core challenges faced in manufacturing, including enhanced traceability, stable quality, and maximized production efficiency.
By utilizing real-time data and applying feedback control based on scientific analysis, the manufacturing process is digitalized and transformed into a robust production system that eliminates dependence on individual operator experience. Shifting toward data-driven manufacturing based on digital technologies will be a key step toward enhancing global competitiveness in future production.
Our company develops, rents, and provides contract dip-coating services using equipment designed with safety in mind. Please feel free to contact us for further consideration.