Scaling High-Reliability Automotive Electronics with Automated Potting and MES Traceability
DSM CASE STUDY
Industry: Automotive Aftermarket
Product Type: Performance Electronics Module (potted assembly)
Services Provided: NPI support, automation integration, custom tooling, MES traceability, final assembly
Customer Overview
The customer is a well-established OEM in the automotive sector, developing and producing electronic systems used in performance and vehicle control applications. Their products require consistent manufacturing processes, high reliability, and strict quality controls to meet both functional and customer expectations.
As demand for a newly launched electronics platform increased, the customer required a manufacturing partner capable of supporting reliable weekly production volumes while maintaining rigorous process control and traceability requirements.
The Challenge
The customer faced several manufacturing challenges as production volumes ramped:
- Establishing a stable final assembly and potting process capable of meeting weekly demand
- Integrating automated dispensing into the production flow while maintaining process control
- Designing custom tooling to support ergonomics and manufacturability
- Maintaining serial-level traceability after potting and encapsulation
- Preventing failed units from entering downstream processes or shipment
These requirements demanded not only production capacity, but close engineering collaboration, automation expertise, and robust manufacturing systems.
The Solution
DSM developed a dedicated, scalable final assembly flow line designed for repeatability, quality, and production flexibility.
Automated Dispensing System Integration
DSM collaborated with the automation supplier to support design and implementation of a custom dispensing solution:
- Supported layout and final footprint of the automated dispensing equipment
- Collaborated on system design, setup, and on-site commissioning
- Ensured smooth integration of dispensing into the overall potting flow line
This approach enabled consistent material application while maintaining throughput and process stability.
Custom Mold Design and Tooling
To support the potting operation, DSM led development of custom tooling:
- Selected and qualified a mold manufacturer capable of meeting technical and schedule requirements
- Worked directly with the supplier to optimize mold design for ergonomics and manufacturability
- Managed phased mold deliveries to support production ramp-up while meeting critical deadlines
The tooling design improved operator efficiency while supporting consistent product quality.
Scalable Flow Line with MES-Enabled Traceability
DSM designed the production flow line to scale with demand while maintaining process control:
- Developed detailed work instructions and trained dedicated, qualified operators
- Designed staffing and station layout to flex with production volumes
- Integrated AEGIS MES to maintain serial-level traceability after potting
- Enabled post-potting serial tracking and production history capture
To prevent nonconforming product from advancing:
- Label duplication was only permitted after successful completion of Stage 1 functional testing
- Failed units could not receive shipping labels, ensuring full containment and traceability
This closed-loop control maintained product integrity through final assembly and shipment.
Results
The integrated manufacturing solution delivered measurable operational benefits:
- Stable, repeatable weekly production output
- Automated dispensing integrated into final assembly flow
- Improved ergonomics and operator efficiency through custom tooling
- Full serial-level traceability maintained after encapsulation
- Strong process controls preventing shipment of nonconforming units
- Scalable capacity to support volume increases
The customer achieved production stability while maintaining strict reliability standards for performance electronics.
Ongoing Partnership
Following successful stabilization and ramp-up of this product line, DSM continues to support additional programs for this customer, providing ongoing manufacturing, engineering collaboration, and process optimization as product volumes and requirements evolve.
Looking to Scale Complex Electronics with Confidence?
DSM supports OEMs in demanding markets with engineering-driven manufacturing, automation integration, and MES-enabled traceability.
Contact our team to learn how we can support your next production ramp or new product introduction.
Reach out today: dsmsales@dynamicsourcemfg.com
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