Application of Computer Integrated Manufacturing
5 in Hard Disc Drive Industry
Agenda
Background
About Seagate Technology, LLC
Components of a Disc Drive
CIM Applications
Quality Function Deployment (QFD)
Design For Manufacturing (DFM)
Automated Disc Drive Assembly Process
Automated Storage and Retrieval System IEM 5303
Advanced
Manufacturing
Summary Systems Design
Slide 1
Questions and Answers 2000 Dennis McInerney
with permission from
John W. Nazemetz
December 6, 2000
Background - About Seagate Technology, LLC
1
Seagate is the world’s largest
manufacturer of disc drives,
magnetic discs and read-write heads
and a leading developer of Business
Intelligence software.
High Volume - Low Variety Industry
• 1400-4300 units per line daily
• 4-10 units per ft2 capacity IEM 5303
• 6-11 people per line Advanced
Manufacturing
• 97 % yield Systems Design
• 88 - 92 % line uptime Slide 2
2000 Dennis McInerney
with permission from
John W. Nazemetz
December 6, 2000
Background - Components of a Disc Drive
6
1. Basedeck 3. Head Disc Assembly
IEM 5303
4. Motor (hidden Advanced
Manufacturing
under HDA) Systems Design
Slide 3
5. Voice Coil 2. Head Stack 6. Top cover 2000 permission from
with
Dennis McInerney
Motor Assembly (not pictured) John W. Nazemetz
December 6, 2000
CIM Applications - Quality Function Deployment (QFD)
2
The QFD is used in the design phase to weight
where design engineering effort should be
focused
QFD Product Planning Matrix Legend Maximize 9 = Strong Relationship
Product: Cheetah 73ES Target 3 = Moderate Relationship
Quality Function Deployment (QFD) Minimize 1 = Weak Relationship
Seek Acoustics <=3.6 bels
Idle Acoustics <=3.3bels
CSA, VDE, EC, UL, …
Power Consumption
HOWs / Inputs
Kano Classification
Ready Time <=7s
Manufacturability
(Objective
Spindle Speed
Winbench Bus
ICBM Support
Measures)
Critical Chain
Winbench HE
Redstone LSI
Product Cost
Cache Size
Importance
Seek Time
Error Rate
Iometer
MTBF
WHATs / Outputs
AFR
CSS
EMI
TPI
BPI
PP
(CTQ's)
Direction of Improvement X IEM 5303
BIC Performance
TTM Schedule
MB 9
MB 10 9
9 9 9 9 9 9 9 9 9
3
Advanced
BIC Price MB 8 9 3 Manufacturing
High Reliability MB 8 9 9 3 9 3 3
Meet Gov/Agency standards MB 10 9
Systems Design
Minimum Capacity MB 10 9 9
Ultra 320 I/F MB 10 9 Slide 4
Quiet Operation 5 9 9
Operating Environment 5 3 9 2000 Dennis McInerney
Storage/Transportation Env. 5 with permission from
John W. Nazemetz
December 6, 2000
CIM Applications - Design For Manufacturing (DFM)
3
DFM APPLIED TO COMPONENTS
EXPERT SYSTEMS
Common Head Stack Assembly
Common Disc Clamp Method
Common tooling points
Common Label placement
WRITTEN GUIDES
Example Head Stack Assembly
IEM 5303
“Tolerance ring design minimum clearance
Advanced
between OD of bearing cartridge and Manufacturing
Eblock bore ID to be .0035”. Systems Design
Example Motor Slide 5
“Bearing cartridge shaft and housing should 2000 Dennis McInerney
with permission from
be stainless steel” John W. Nazemetz
December 6, 2000
CIM Applications - Automated Disc Drive Assembly Process
3
Macro View Disk Drive Assembly
SUB DRIVE PCBA DRIVE FINAL
ASSEMBLE ASSEMBLE INSTALL TEST PACK
DRIVE
Our focus Disk Drive Assemble ASSEMBLE
Breather Lower
Manual Motor Media Spacer
Filter Magnet
LOAD Install Stack Install
Install Install
IEM 5303
Flex Head Advanced
Screw Balance Balance Clamp Disk
Stack
Correct Measure Install Bias Manufacturing
Install Install
Systems Design
Upper Top Drive Slide 6
Merge Magnet Cover Unload
2000 Dennis McInerney
Install Install to Test
with permission from
John W. Nazemetz
December 6, 2000
CIM Applications - Automated Disc Drive Assembly Process
3
Use of Robotics and Conveyors
Robots custom built from scratch
Video Example from Media Stack to
Balance correct Media
Stack
Spacer
Install
Balance Balance Clamp Disk
Correct Measure Install Bias
IEM 5303
Advanced
Manufacturing
Systems Design
Slide 7
2000 Dennis McInerney
with permission from
John W. Nazemetz
December 6, 2000
CIM Applications - Automated Disc Drive Assembly Process
2
Use of Robotics and Conveyors
Video Example from Top Cover Install
and Screw
Top
Cover
Install
IEM 5303
Advanced
Manufacturing
Systems Design
Slide 8
2000 Dennis McInerney
with permission from
John W. Nazemetz
December 6, 2000
CIM Applications - Automated Disc Drive Assembly Process
2
Use of Barcoding
Placed on pallet and read by each
station
Product configuration
Product attributes (HGA #, HSA #)
Times and quantities
Station material replinishment
Lot traceability
IEM 5303
Advanced
Manufacturing
Systems Design
Slide 9
2000 Dennis McInerney
with permission from
John W. Nazemetz
December 6, 2000
CIM Applications - Automated Disc Drive Assembly Process
2
Use of Computer Integration
Host computer controls each station
• Product Configurations
• Business Data(times, quantities)
• Lot Traceability Business
• Station Sensors Server 1
Business Server 2
(conveyor, robots)
Server Server
• Station Bin
Ethernet
Replinishment IEM 5303
Host
Line 1
Host
Line 2
Advanced
Manufacturing
Hub 1 Hub 2 Systems Design
Line 1 Line 2 LOAD 1
LOAD 1 Slide 10
2000 Dennis McInerney
with permission from
John W. Nazemetz
December 6, 2000
CIM Applications - Automated Storage and Retrieval System
3
ASRS in Finished Goods (new products)
Single Command Cycle 18 aisle, 7
stories
Receiving first floor
Product lines on above floors
Product lines use for finished goods
Labor cost reduction
Minimize Drive Shock from handling
Minimize electrostatic discharge IEM 5303
Advanced
Control inventory for multiple Manufacturing
customers Systems Design
Slide 11
2000 Dennis McInerney
with permission from
John W. Nazemetz
December 6, 2000
CIM Applications - Automated Storage and Retrieval System
3
Horizontal Carousel in Finished Goods
(repair products)
Store repaired drives
Most frequently used close at hand
Packaging To
Packaging Horizontal Material
Display
via Carousels Flow
Conveyor with Light
with quantity
Bars
and 1
location Incoming IEM 5303
Conveyor
Repaired Advanced
lights Drives
Manufacturing
Pull
Systems Design
Pull
Racks Racks Slide 12
with 2 3
Light 2000 Dennis McInerney
Display with permission from
John W. Nazemetz
December 6, 2000
Summary
4
CIM Applications in Disc Drive Industry
Span product life cycle
Some are non technical
QFD
DFM Guidelines
“Expert” systems to written documents
Some are technically complex
Automation (Robots, conveyors, etc.)
Computer Integration IEM 5303
Advanced
ASRS Manufacturing
Systems Design
Slide 13
2000 Dennis McInerney
with permission from
John W. Nazemetz
December 6, 2000
Questions and Answers
?
IEM 5303
Advanced
Manufacturing
Systems Design
Slide 14
2000 Dennis McInerney
with permission from
John W. Nazemetz
December 6, 2000