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America Quartz Know-how (AQT) specializes within the manufacturing and processing of fashioned quartz merchandise for the electronics and semiconductor industries at its plant in Hue, Vietnam. The manufacturing of AQT’s merchandise calls for the very best degree of meticulousness and accuracy.
Challenges
Beforehand, elements had been processed manually, with employees performing excessive temperature heating processes. This harmful and repetitive work meant that employees turnover was excessive, with an elevated threat of accidents. There was additionally the chance of errors that would result in severe manufacturing losses.
To resolve these challenges, AQT determined it wanted robots that might keep away from labor shortages, scale back threat and enhance productiveness.
Resolution
Having used ABB robots at its vegetation within the U.S., AQT approached ABB for an answer for its Hue plant. The result’s a robotic manufacturing cell consisting of an ABB IRB4600 industrial robotic, an IRB2600 industrial robotic and a moulding machine.
The ABB IRB4600 picks up the quartz workpiece and locations it into place for the warmth remedy course of. Following this, the IRB2600 robotic heats the workpiece evenly. Then, the cylinder mechanism sucks the heated quartz plate into the mould and shapes it. After 30 seconds, the vacuum valve shuts off, and the IRB 4600 robotic removes the product and repeats the cycle.
Outcomes
For the reason that introduction of the robots, plant effectivity and efficiency has been considerably improved, with 5 occasions fewer faulty merchandise resulting from manufacturing errors.
“Utilizing the answer offered by ABB, our merchandise are actually constantly accomplished to the very best high quality, with much less handbook intervention required and a discount in errors. Circumstances have additionally improved for employees as all the harmful and repetitive work is now taken care of by the robots,” stated Tran Phuoc Thanh Vu, manufacturing unit supervisor, America Quartz Know-how.
One other enchancment has been a dramatic discount in manufacturing cycle occasions. With the robotic course of, manufacturing time has been diminished from 25 to only 5 minutes, with a present common output of 100 items a day, a four-fold improve on the earlier manually-based manufacturing course of.
“The answer brings huge worth to the plant – it improves manufacturing capability, ensures on time supply of buyer orders and gives excessive stability in the course of the manufacturing course of,“ stated Vu. “We all the time purpose to have a contemporary {and professional} manufacturing unit, utilizing the most recent strategies and applied sciences to realize a lean manufacturing course of and enhance productiveness. Our good expertise with ABB robots implies that we plan to put money into a number of robotic stations for the plant within the coming 12 months.”