EV Assembly Line Automation
- DATE
- January 23, 2026
- CLIENT
- FDI manufacturing partner
- CATEGORY
- Robotics & MES
- LOCATION
- Hai Phong, Vietnam
Optimise production cycle time and eliminate cumulative machining error across complex mechanical assemblies. The customer faced high scrap rates and unplanned maintenance costs, requiring a synchronised automation line with strict micro-tolerance inspection standards.
Challenge & solution
CHALLENGE & SOLUTION
The partner plant struggled to keep high-speed stamping and the CNC machining cell stable together. Manual steps interrupted material feeding, created serious bottlenecks and wasted special alloy material. TOP WELL built a complete solution:
Eliminated dynamic vibration and thermal drift during 24/7 CNC operation.- Automated blank feeding and non-contact optical measurement to ±0.002 mm.
- Integrated SCADA/MES industrial communication for real-time equipment monitoring.
- Transferred standardised SOP operation procedures to the on-site engineering team.
Implementation process
OUR PROCESS
Delivery followed German and Japanese industrial practice: site survey, 3D DFM/Moldflow simulation, finishing on 5-axis machining centres, Renishaw laser calibration and on-site FAT/SAT acceptance before connecting to live production.
Results & impact
RESULTS & IMPACT
After handover the project delivered a step change in real operating capability, set a new benchmark for mechanical reliability and helped the partner meet demanding global supply-chain standards:
- 35% lower operating cost and 98% less unplanned downtime.
- Overall equipment effectiveness (OEE) raised from 76% to 94.2%.
- Return on investment (ROI) achieved after 14 months of operation.
- International quality certification to ISO 9001 and AS9100.