Modular Drive Process System Design for Optimal Factory Efficiency September 9, 2010

Transcription

1 Modular Drive Process System Design for Optimal Factory Efficiency September 9, 2010 Presenter: Pete Goglia Contributors: Mark McCrimmon, Kevin Richardson, Nick Granger-Brown

2 Modular Drive Process System Design for Optimal Factory Efficiency The test process for disk drives is an integral part of the manufacturing process and includes: Testing the drive for compliance to production specifications Adds value to drives by completing the manufacturing steps such as channel and servo tuning as well as flaw mapping Elements to consider in Drive Test equipment design: Drive manufactures follow a variety of process flows New Technology introductions are required to achieve higher density and capacity Drive factories strive to achieve a balance of technology and capacity growth while at the same time maintaining factory efficiency. Equipment must be designed with future product requirements in mind to insure the best ROI and total cost of ownership. This presentation examines: Drive test requirements, Tradeoffs that are faced by capital equipment providers How total factory efficiency can be achieved through modularity and flexibility in the processing equipment. 2

3 Contents Designing for a wide range of market requirements HDD manufacturing process complexity: HDD Test Requirements Technology complexity: Areal density changes HDD test Manufacturing Efficiency: Drives Process change Tradeoffs faced by HDD Manufacturers Tradeoffs faced by capital equipment providers Modularity: How total factory efficiency can be achieved 3

4 Designing for a Wide Range of Market Requirements 4 Class FF Speed Interface Capacity Mobile ,200 RPM 5,400 RPM 7,200 RPM Desktop 3.5 7,200 RPM Enterprise Consumer Electronics ,000 RPM 15,000 RPM 4,200 RPM 5,400 RPM 7,200 RPM PATA SATA PATA SATA FCAL SAS SCSI PATA SATA 80 GB 120 GB 160 GB 250 GB 320 GB 400 GB 500 GB 640 GB 750 GB 1 TB 160 GB 250 GB 320 GB 500 GB 750 GB 1 TB 2 TB 147 GB 300 GB 450 GB 600 GB 160 GB 250 GB 320 GB 500 GB 640 GB 750 GB 1 TB 1.5 TB 2 TB Sources: TrendFocus and WD, Seagate, HGST, TSDC, Samsung websites And also a variety of other specs Vibration Shock Temperature USB Consequently WD offers over 60 different external drives Seagate has over 40 types of enterprise drives HGST s portfolio includes at least 55 different 3.5 drives TSDC has over 70 PC-grade drives Samsung offers more than 50 different mobile drives Leading to a total of over 750 various drives in the industry

5 HDD Manufacturing Process Complexity: Drives Test Requirements 5 Relative Dynamic Isolation Performance ASSEMBLED DRIVE Temperature Profile

6 Technology Complexity: Areal Density Changes HDD Test INSIC Targets Test Time increase from x to 2.5x Dynamics requirements increase from x to 3x 6 Sources: INSIC August 2010

7 Process complexity needs modularity Do not burden the whole HDD test process equipment with capabilities only used in one part of the process. Not cost effective Process can change and evolves as do HDDs Some capabilities today may not be required in the future Use modularity To create test system building blocks that deliver specific performance and capability Use test building blocks to configure the test system to match the HDD test process To reconfigure the test process in line with changing production, process and capability needs To enhance the process with the creation of new technology and capabilities now and in the future that can easily adopted within existing infrastructure Modularity can optimise production capability. 7

8 Manufacturing Efficiency: Drives Process Change HDD factories need improved efficiencies Reduced cost of ownership Better ROI on investments Reduced capital cost per HDD shipped Green Initiatives Reduced power consumption benefits the environment and Cost of ownership Higher Throughput Higher test floor density more HDD/sq.ft Reduce or slow down critical investment in new factories until everything is maximum productivity achieved from factory space Reduce amount of equipment on the test floor Consolidate HDD test steps and equipment Timing Want it now. 8

9 Manufacturing Efficiency: Drives Process Change AVERAGE DRIVE PRICE TREND FOR SEAGATE, WESTERN DIGITAL AND HGST (Q4 98 TO Q1 10). Capital Spend per HDD continues to increase as ASP reduces Continued pressure on Manufacturing Operations to make factories more efficient and achieve higher productivity with HDD processing equipment Source: 2010 Hard Disk Drive Capital Equipment Market and Technology Report, Coughlin Associates, June

10 Tradeoffs Faced by Capital Equipment Providers Develop a universal HDD test tool that can test all HDDs but not Optimized to production or HDD test process demands VS Develop a highly flexible tool that is optimized for production and process requirements now and in the future Provide equipment that can re-utilize existing legacy equipment investment VS Provide lead-edge test HDD test Performance and capability Provide HDD test equipment with the highest density of HDDs under test per sq.ft of real estate VS Ensuring maximum flexibility to test HDDs of different form factors (heights) within the test system 10

11 Modularity: How Total Factory Efficiency Can Be Achieved Don t develop the fixed size, fixed configuration Tester Test equipment is not like that It will not be optimal for rapidly changing HDDs and HDD processes Modularity Configurable system architecture Configurable infrastructure or framework made up of modules that can be arranged to meet different factory needs and requirements, eg Height, length A range of Pluggable HDD test Cells into the infrastructure are optimized for different HDDs and different HDD processes. Ease of upgrade Reconfiguration of cells and the introduction of new compatible cells with different characteristics is easily achievable as needs evolve Capital equipment reuse Provide a path to reuse existing legacy investment hardware in new products more efficiently 11

12 Modularity: How Total Factory Efficiency Can Be Achieved Flexibility Mix and match new and legacy technologies where it makes sense, with forward and backward compatibility, this improves capital investment and ROI A configured system made up of different cells supporting the different parts of the HDD process can be a one stop shop for different HDD processes. This can improve operational efficiency, reduce handling, space and cost of ownership. Can be reconfigured as and when needed easily by the customer in line with HDD test process changes or the introduction of new HDDs Introduction of New Technologies New HDD test technologies designed into pluggable cells will be compatible with the modular system. New cell Roadmaps are essential to protecting existing equipment investment and at the same time introducing new technologies and capabilities into the HDD process. 12