Automated system for SSD/DRAM Module Manufacturer for efficient manufacturing process.
Case in point: SSD and DRAM Module Manufacturer
At a glance
Focus: Automated system for SSD/DRAM Module Manufacturer for efficient manufacturing process
Challenge: SSD and DRAM Modules are manufactured using SMT (Surface Mount Technology), with post-reflow processes previously done manually by operators — resulting in inconsistent and low product quality. Getech was invited to build an automation system to replace these manual processes.
Approach: Getech developed Robotic Automation Machines using SECS/GEM software protocols, networking all machines via LAN ports for instantaneous digital data transfer among machines and servers — enabling real-time process fine-tuning and instantaneous access to vital data (product firmware, label templates) from a cloud repository server.
Impact: Scalable processes with best product yields and product quality, consistent processes, ongoing OEE monitoring and improvement, and affordable machine prices that met the customer's ROI targets.
Getech Automation
Getech designs and manufacture industrial automation machine and equipment under the GETECH brand. These machines are used in the electronics, semiconductor, pharmacy, medical equipment and defence equipment manufacturing industries.
SSD and DRAM Module Manufacturer
This Client is a world leader in innovative memory solutions that transform how the world uses information. They have been instrumental to the world’s most significant technology advancements, delivering optimal memory and storage systems for a broad range of applications. The company is a major manufacturer of memory and storage technologies - DRAM, NAND and NOR technology.
Business challenge
SSD and DRAM Modules are manufactured using SMT (Surface Mount Technology), with post-reflow processes previously done manually by operators — resulting in inconsistent and low product quality. Getech was invited to build an automation system to replace these manual processes.
SSD and DRAM Modules are manufactured using SMT (Surface Mount Technology). Post reflow processes are done by operators manually resulting in inconsistent and low product quality.
Getech was invited to build an automation system to replace the manual processes. Some of the processes are digitized with new network resulting in quality and efficiency improvement.
Industry 4.0 solution
Getech studied the manual processes and designed an automated system to replace them the steps.
Next challenge was to network the machines and software protocols to exchange data among machines as well as cloud repository servers.
Getech has developed Robotic Automation Machines (Green icons in below picture) with SECS/GEM software protocols. All the machines are networked with LAN ports. Digital data is instantaneously transferred among the machines and servers. Process is fine-tuned real-time basis. R&D releases vital data through cloud repository server. Machines use latest vital data such as product firmware, and label templates from cloud repository server instantaneously.
Reflow is last process in PCBA assembly process.
AOI (Automatic Optical Inspection) checks for SMT component and process visual defects
RBM is a depanelizing/routing mechanical process.
Sorting is a routing quality inspection and sorting process.
Testing is a functional test process.
CTO is a Configure to Order process which is downloading the firmware to SSD and labelling.
Box packing is packing the SSD or DRAM Modules in carton box ready to ship.
All Getech machines update SECS/GEM host machine with machine status such as Idle, Setup, Executing, Pause. Using this data server generate OEE reports. OEE reports helps engineers to focus on improving the process continuously.
Sorting machine receives AOI inspection results for every product on real time basis over the network. Sorting machine is integrated with routing inspection process. It uses AOI inspection results and local routing inspection data to sort the products into tray bins.
RBM machine receives routing inspection results from Sorting machines over network real time basis. RBM machines uses routing inspection results and compensate routing machine recipe instantaneously. This real time feedback helped to improved consistent product quality and Cpk of depanelizing process.
CTO machine uses latest firmware and label templates from cloud repository. Even though R&D is in different geographical location the product produced is with latest firmware and label templates. Customer R&D releases firmware and label temple templates as when needed through cloud repository servers. No manual intervention is needed.
Key benefits
| Area | Outcome |
|---|---|
| Quality | Scalable processes. Best product yields and product quality |
| Operational Benefit | Consistent process. |
| Visibility & Analytics | OEE monitoring and improving |
| Operational Benefit | Affordable machine prices to meet customer ROI targets |
Technologies used
Change management and implementation
Few challenges in implementing these solutions.
Each machine UPH (units per hour), Cost and Size are critical parameters to achieve acceptable ROI. SECS/GEM protocols are new to PCBA (printed circuit board assembly) process. It has taken lots of software designers time in developing specific protocols. As the server infrastructure is provided by customer, customer support was key in implementing networked processes. Understanding manual process and digitization formats were critical.
Development machines were done in phased manner to reduce the risk of each project. First proof-of-concepts developed and tested for key features. Then actual machines were developed.
Customer gave price target to make the solution workable. Machine prices and costs were kept low to achieve 3-years break-even targets.
Developed SECS/GEM protocols and software with re-usable software components to keep the costs low.
Design and development lead time kept to a low of 16-20 weeks
Projects were staggered to reduce the stress on development team
Trained sub-contractors to manufacture machines for repeat order machines while Getech focus on new product design and development.
Deployment and post installation support services for non-Singapore sites were supported through authorized Getech distributors. Getech has authorized distributers across the world to support its machines.
SSD and DRAM Modules are evolving. New form factors and products released which required continuous improvement in machines. Getech upgrades machines to suit new SSD and DRAM module products.
Each solution/machine developed through phases. On-site machine upgrades are done to keep up with changing needs of customers.