Application of Computer Integrated Manufacturing in Hard Disc Drive Industry

IEM 5303Advanced

Manufacturing Systems Design

2000 Dennis McInerney with permission from

John W. NazemetzDecember 6, 2000

Slide 1

Application of Computer Integrated Manufacturing in Hard Disc Drive Industry

AgendaBackground

About Seagate Technology, LLCComponents of a Disc Drive

CIM ApplicationsQuality Function Deployment (QFD)Design For Manufacturing (DFM)Automated Disc Drive Assembly ProcessAutomated Storage and Retrieval System

Summary

Questions and Answers

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Slide 2

Background - Background - About Seagate Technology, LLCAbout Seagate Technology, LLC

Seagate is the world’s largestmanufacturer of disc drives,magnetic discs and read-write headsand a leading developer of BusinessIntelligence software.

High Volume - Low Variety Industry• 1400-4300 units per line daily• 4-10 units per ft2 capacity• 6-11 people per line• 97 % yield• 88 - 92 % line uptime

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Slide 3

Background - Background - Components of a Disc DriveComponents of a Disc Drive

6. Top cover (not pictured)

1. Basedeck 3. Head Disc Assembly

5. Voice Coil Motor

2. Head Stack Assembly

4. Motor (hidden under HDA)

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Slide 4

CIM Applications - CIM Applications - Quality Function Deployment (QFD)Quality Function Deployment (QFD)

The QFD is used in the design phase to weight where design engineering effort should be focused

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QFD Product Planning Matrix Legend Maximize 9 = Strong RelationshipProduct: Cheetah 73ES Target 3 = Moderate RelationshipQuality Function Deployment (QFD) Minimize 1 = Weak Relationship

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BIC Performance MB 9 9 9 9 9 9 9 9 9 9TTM Schedule MB 10 9 3BIC Price MB 8 9 3High Reliability MB 8 9 9 3 9 3 3Meet Gov/Agency standards MB 10 9Minimum Capacity MB 10 9 9Ultra 320 I/F MB 10 9Quiet Operation 5 9 9Operating Environment 5 3 9Storage/Transportation Env. 5

WHATs / Outputs(CTQ's)

HOWs / Inputs(ObjectiveMeasures)

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Slide 5

CIM Applications - CIM Applications - Design For Manufacturing (DFM)Design For Manufacturing (DFM)

DFM APPLIED TO COMPONENTSEXPERT SYSTEMS

Common Head Stack AssemblyCommon Disc Clamp MethodCommon tooling pointsCommon Label placement

WRITTEN GUIDES Example Head Stack Assembly

“Tolerance ring design minimum clearance between OD of bearing cartridge and Eblock bore ID to be .0035”.

Example Motor“Bearing cartridge shaft and housing should be

stainless steel”

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Slide 6

CIM Applications - CIM Applications - Automated Disc Drive Assembly ProcessAutomated Disc Drive Assembly Process

Macro View Disk Drive AssemblyFINALPACK

DRIVETEST

PCBA INSTALL

DRIVE ASSEMBLE

SUB ASSEMBLE

DRIVE ASSEMBLEOur focus Disk Drive Assemble

DriveUnloadto Test

TopCoverInstall

FlexScrewInstall

HeadStackInstall

UpperMagnetInstall

Merge

SpacerInstall

BalanceCorrect

BalanceMeasure

ClampInstall

DiskBias

MediaStack

LowerMagnetInstall

MotorInstall

BreatherFilterInstall

ManualLOAD

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Slide 7


Use of Robotics and Conveyors Robots custom built from scratch

SpacerInstall

BalanceCorrect

BalanceMeasure

ClampInstall

DiskBias

MediaStack

Video Example from Media Stack to Balance correct

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Slide 8


Use of Robotics and Conveyors Video Example from Top Cover Install and Screw

TopCoverInstall

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Slide 9


Use of BarcodingPlaced on pallet and read by each

stationProduct configurationProduct attributes (HGA #,

HSA #)Times and quantitiesStation material replinishmentLot traceability

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Slide 10


Use of Computer IntegrationHost computer controls each station

• Product Configurations• Business Data(times, quantities)• Lot Traceability• Station Sensors(conveyor, robots)• Station BinReplinishment

Ethernet

Hub 2

HostLine 2

HostLine 1

Hub 1

Server Server

LOAD 1LOAD 1Line 1 Line 2

BusinessServer 1

BusinessServer 2

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Slide 11

CIM Applications - CIM Applications - Automated Storage and Retrieval SystemAutomated Storage and Retrieval System

ASRS in Finished Goods (new products)Single Command Cycle 18 aisle, 7

storiesReceiving first floorProduct lines on above floors

Product lines use for finished goodsLabor cost reductionMinimize Drive Shock from

handlingMinimize electrostatic

dischargeControl inventory for multiple

customers

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Slide 12

CIM Applications - CIM Applications - Automated Storage and Retrieval SystemAutomated Storage and Retrieval System

Horizontal Carousel in Finished Goods (repair products)Store repaired drives

Most frequently used close at hand

PackagingDisplay with quantity and location lights

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Slide 13

Summary Summary

CIM Applications in Disc Drive IndustrySpan product life cycleSome are non technical

QFDDFM Guidelines

“Expert” systems to written documents

Some are technically complexAutomation (Robots,

conveyors, etc.)Computer IntegrationASRS

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Slide 14

Questions and Answers Questions and Answers

??

Documents

Application of Computer Integrated Manufacturing in Hard Disc Drive Industry