Painting Factory Tour: How Computer & Vehicle Parts Are Painted | Automated Factory Tour

by birtanpublished on October 1, 2020

Paints is one of the chief processes to
dial in for product manufacturing and
today's tour will bring us to a
taiwanese factory replete with a mix of
automated and handcrafted painting
procedures and this tour will see
robotic arms that allow high precision
detailing of small crevices in the
products but trade off with less precise
sprayers in raw speed will also learn
about ovens for baking the paint filters
for cleaning and reusing water and
getting government environmental
clearance quality control and dust
control that would be useful in hair
product commercials and we'll also look
at machines for UV or PCB finishes that
are also present in this highly
specialized factory some computer
components have more specialty finishes
than others the es10 cute video card or
waifu 5700 xt for instance not made here
both have some added purely functional
glitz and glam for the products in a
more standard way cases like the digital
storm bolt which is made by Lian Li have
to get their metallic shine and hardened
brilliant paint jobs somewhere and this
Factory is where those cases are made
along with some other parts that we'll
see today before that this video is
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products don't often start the color
they end up as we've shown in our raw
materials factory tour previously metals
arrive in the color that you'd expect
they're big gray sheets of aluminum or
steel and they need to go through the
entire metal cutting process whether
that's with lasers or MCT machines and
stamping process before getting painted
some parts like internal chassis
components never need painting and can
remain their raw metal finish Lee Anne
Lee tells us that this is the difference
between sec C and s GCC steel s GCC will
apparently corrode if left unpainted and
is the more common choice for steel
factories in China under the assumption
that they will get painted before final
production S ECC will not corrode if
left alone we're told and so as a safer
choice for the inside of a router or a
switch for example a lot of that in from
in our tour of house side panels get
made so check that video for more
information on the step that precedes
this one painting is hard to do right
when looking at something like a case a
white finish between plastic and metal
parts is difficult to match and it
requires a lot of back-and-forth ardi
with the painting factories for a step
that's before even this painting step
special finishes like digital storms
metallic blue one that's brokered by Lee
and Lee are even more difficult to get
right without any blemishes the factory
were touring in Taiwan today is highly
specialized they do lower volume than
some other paint shops but they focus
hard with quality and having space set
up for lower production quantities of
specialized products the first step to
any factory like this is dust control
this Factory had us go through a fairly
standardized air chamber to blow away
the dust on our clothes
although jokes may have been told by our
hosts that it was to get rid of the
human malware from visitors each visitor
has to wear shoe covers as well and even
the floor has a special coating to help
dust particles stick to it rather than
float in the air floor mats and floor
coating everywhere help keep the dust on
the ground as a dust particle landing on
a product or a panel could completely
ruin the paint job you'll see this level
of care taken everywhere else in this
factory – even one of the conveyor belts
that we'll look at later uses an
anti-static material for the belt which
prevents dust buildup to the felt
surface and there's a whole lot of
compressed air used in this Factory
after going through dust control we
arrive at the first step in the factory
which is product preparation the factory
sprays off any products entering the
paint line with high pressure compressed
air and also applies an oil coating to
the product we had some translation
difficulties here but we're assuming
that it's just a cleaning agent like
rubbing alcohol are similar although our
translator noted that it might be to
help paint stick to the surface the air
prep and the coating is applied by hand
for some products but can be done by
machine for others it all depends on
machine time and what the customer wants
and how complex the product is this
particular product is for a common air
conditioning unit in Taiwan and is
relatively simple as compared to the
more complicated stuff that we'll look
at momentarily for this one after its
cleaned it goes straight into the
automated spray booth these types of
booths are used for products that don't
have complicated designs or deeper
apartments so for a straight sheet of
plastic like this it's perfect the
machine uses a spray nozzle that's moved
left to right by a belt which is hooked
up to the paint supply in another room
the nozzle only takes about one second
to cover the entire left to right area
of the product but it makes multiple
passes for additional layers and it can
slightly adjust to the nozzle angle or
the height with each pass the paint
sprayer is programmed by a computer in
the room and is set for each product
individually once one side of the
products is coated the carrier is
instructed by automation to rotate and
the nozzle arm can be lowered to hit the
underside of the product or other areas
that were harder to reach this booth
isn't used for as strictly controlled
products as some of the others so the
paint's isn't stored with as many dose
prevention measures as a couple of the
more extreme booths that will look at
momentarily for this one a paint bucket
and the air compressors are contained
within a room walled mostly with steel
secured behind the paint booth waterfall
and behind a few doors to keep it away
from particulate matter as for the paint
excess and the fume control the booth
has a waterfall in the back supplying
filtered water to help absorb the excess
paint the heavier paint sinks to the
bottom of the pool and the water helps
keep it loose preventing gunk buildup
this paint filled water is drained into
large vats and filtration systems that
we'll talk about later in this video
air intake is measured by a meter
mounted to the wall to ensure adequate
air flow to pull the fumes out of the
room and there's a lot of duct work as
well all of the air is pulled out of the
room via ductwork with high-grade
filters and the air is sent through a
roof-mounted ventilation machine before
it's released we'll look at one of these
in an upcoming electroplating factory
tour as well but we didn't get to see
the rest of the filtration above the
factory here for this air conditioning
chassis component the last few steps are
pretty simple
the parts are picked up on trays and
placed onto a conveyor belt where they
go through a lawn oven for a rapid dry
the oven bakes up to 70 degrees Celsius
but it typically averages around 40 for
products once the parts emerge there
grabs for QC and passed or failed minor
blemishes like a blob of paint can
sometimes be sanded off and approved
while other failures might just require
a full rework or reapplication of the
paint while walking from this part of
the factory
higher-end area we walked by some
printed circuit boards as well that are
being coded as more of a favor we're
told it's not a common product the
factory doesn't make enough of these to
really make much money on them but
they're helping out anyway the PCBs are
provided elsewhere but they're sprayed
with a protective coating at this
Factory the shiny thick coating is
important for this particular PCB
because it's going to be deployed
outside for years these PCBs go to wind
turbines in Taiwan so the coating is
done by the factory to help protect it
from Taiwan's humidity it doesn't have
to be paint apply to the factory despite
what they specialize in it can be any
type of coating like
polyurethane or whatever they're using
on this PCB the next section of this
Factory is where Lee Ann Lee hires the
factory to paint some of its higher-end
products like the digital storm bolt
case case panels are painted in the same
style of booth shown a moment ago just
with more dust control in place for this
floor this booth has been busy painting
scooter parts lately and if you've ever
been to Taipei you know how big that
business is the arm moves the same way
and the water usage for waste management
remains the same as well once the parts
go through the oven on this floor
they're sent downstairs on a conveyor
belt the packaging which again helps
with dust control rather than carting it
around by hand one key point with this
Factory is that all packaging remains on
a completely separate floor that's
isolated from the painting supply
because cardboard box particles get
everywhere in ruined products with wet
paint there's a lot of thought that goes
into factory layout for dust management
and that becomes clear pretty quickly
another optional step is for products to
go through a UV coating process this
floor had two UV coating machines on the
same conveyor belt each capable of
different degrees of cony
these machines are used for hardened
outer coats of protection mostly useful
for stuff that will be outside or just
might need some endurance
against any kind of handling we're told
that these machines can go up to 8h and
hardness but are often at 1 to 2 H we
didn't get a full translation on what
scale is being used here but some of our
viewers probably know about this process
and you can post your thoughts below
polyurethane coating is also applied in
this facility for products that require
it it was at this point that we asked
about units that fail validation
failure rate even with all of these
controls is still as high as 10% on some
products this is products that failed
but are caught by the factory so they
don't go out to the customer we're told
that the most common causes of failure
are uneven paint jobs scratches in the
product exterior as it was provided by
the customer so the factory can't fix
that and errant dust most failures can
be reclaimed with a light sanding by
manual labor while products that can't
easily be recovered are sent through the
entire process all over again most
products can simply be painted over but
some require paint removal first if it's
a smaller product where the extra
thickness of one more layer of paint
might matter the next line we went to
was the most advanced to one of the
factory this one is the line leading to
the robotic arm which the factory has
had for 10 years now products entering
this paint booth are sprayed with an air
compressor by hand first one at a time
and then placed on an anti-static
conveyor belts to be led into the prep
room optical sensors in the conveyor
belt stop the belt once the line of
products reaches the other side at which
point a worker can place them at the
machine for being painted this belt is
only a few feet long so it's not really
for ease of movement or accessibility of
the parts but more about yet again more
dust control and fume control only using
the conveyor belt minimizes the open air
between the paint booth and the prep
room and air nozzles inside the conveyor
belts keep the dust in the preparation
area as the products roll through the
products are sprayed with compressed air
one more time on the other side and then
coated with a cleaning agent we'd assume
this level of paranoia about quality
control only emerges from experience of
lost products the robotic arms
articulation here allows more accurate
detailing of small areas of the products
but it can't coat as much as quickly
when we asked the factory why they
didn't have more of these robotic arms
in place they told us it was entirely to
do with speed for something like an air
conditioner front panel it makes more
sense to coat as many at a time as
possible the robotic arm takes about 2
times longer for products to paint then
the first spray booth does so using this
sparingly for complicated jobs is the
most responsible way to use it when
they're trying to also deal with volume
this drives up cost for the customer of
course because machine time is
everything but sometimes
no way around that the room is
completely sealed other than the
conveyor belt which uses air to keep the
dust out metal walls are used since dust
could otherwise work its way into the
room through small cracks or pores where
walls meets the lighting is also bright
in this room and of a specific light
temperature as the technician needs to
be able to identify by eye whether the
color is correct the room itself is also
temperature controlled and like the
others
heavy ventilation is in place as for the
paint even that's more controlled than
elsewhere the paint buckets are secured
in an entirely metal room with limited
ventilation this room is sealed behind
two metal doors that seal floor to
ceiling and people only have access to
this room to change the paint tubes run
from the compressors to the paint booth
lines and this factory as far as paint
consumption goes it uses about 1,200
gallons of paints in a month although we
should note that we're not sure if
they're using US gallons or imperial
gallons for whatever that's worth once
the product is donek goes to another
cleaning bath and a visual acuity
inspection the next machine is the most
important machine and it's probably the
most heavily used it's the logo stamping
machine likely in high demand since so
many companies just buy stuff and put
their sticker on Coursera probably has a
whole line of logo stamping machines and
a conveyor belt of stuff from ASA tack
this machine requires fifteen to twenty
minutes alone to warm up and it needs to
be warmed up prior to use the stamp is
made for the logo and it's punched down
onto the product with metallic prints
specifically benefiting from this
approach once dance the products are
loaded onto a cargo elevator and sent to
another floor for polishing and
packaging polishing work is manual and
only used for products that really
require it polishing wheels are used for
the step and technicians work on it by
hand for parts that need it an
additional darkroom is available as a
gigantic oven for products to just sit
and bake this room can cook up to 200
degrees Celsius but it can also be
programmed for temperature control over
a prolonged drying period if the company
determines that certain paints dry
better with a temperature ramp up and
down they can program that into the room
on average it takes about 40 minutes to
heat plastic finally everything is
packaged and box
another floor and then sent out by truck
to the customers the last part of the
factory pertains to waste management
which is a critical part of a paint
factory
especially in Taiwan where the
environmental regulations are pretty
strict the government will drop by
unannounced and test the water coming
out of the factory
so factories like these conform to
strict standards the wasted oil paint
and contaminated water are all sent
through a giant filtration machine
that's mounted out the window of the
factory you have to walk through the
window to get to it it's not really
meant to be accessed by people this area
smelled pretty toxic and the air was
thick with the smell of paint and
cleaning agents mixing together the
waste goes through multiple filter
machines and series coming down from
pipes upstairs and leading from the
paint booths originally soap and water
are applied as our cleaning agents and
then filter after filter after bag after
filter are used to clean the waste water
cleaned in this process we'll return to
the paint booths
while the foamed up paint and the oil
gets filtered down into collection bags
in translation the company described
this as a concrete like material that's
sent out to a government certified
company for waste management the waste
is further processed if necessary and
whatever can be burned out is burned
while the hazardous waste is disposed of
elsewhere water is eventually added to
the machine from evaporation over time
but it's mostly recycled and reused
because well one that's cheaper and –
they filtered it enough where they can
it was here that we also walked by a
paint prep room where we learned that
the paint comes in a concentrate and has
a solvent manually added to it this is
where the paint for future spray jobs
would be located the products after all
of this are finalized the digital storm
panel by Lian Li goes through painting
UV coating polishing sanding and
multiple baking steps which gets the
brilliant shine that it gives off the
factory also showed us a coating that
can use for things like – anti fog
common on scooter parts for covering
speedometers or meters and preventing
Taiwan's weather from making them
illegible although it wasn't translated
we'd know enough Mandarin to understand
the conversation that took place around
this anti-fog coating our guide simply
asked queima and the
actually replied Heung whay so it's not
cheap to do that kind of coding but this
Factory is a specialty shop for a reason
as always check back for more factory
tours subscribe to the channel we have a
lot of them coming out over the next
couple of weeks and we have a whole
factory tour playlist linked in the
description below if you want to check
out some of our previous tours support
us directly in these efforts by going to
patreon.com slash gamers Nexus or you
can get something in exchange for
supporting us at store that gamers
access not net thanks for watching we'll
see you all next time

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