America Quartz Technology (AQT) has significantly enhanced its manufacturing efficiency by integrating ABB robots into its production line in Hue, Vietnam. This strategic move has not only minimized manual labor but also drastically reduced production errors and cycle times. The development indicates a significant shift towards automation in the semiconductor industry, promising improved safety and productivity for the workforce.
ABB Robots Description
ABB’s IRB4600 and IRB2600 are advanced industrial robots designed for precision and efficiency in manufacturing processes. Launched by ABB in 2006, the IRB4600 is known for its compact design and high-speed operations, while the IRB2600, introduced in 2009, excels in flexible, high-performance automation. These robots are widely utilized in various industries, encompassing tasks from assembly to material handling, ensuring optimized production workflows.
America Quartz Technology faced numerous challenges before adopting robotic solutions. The manual processing of quartz components, which involved high-temperature heating and repetitive tasks, resulted in high staff turnover and increased risks of accidents. Errors in the manual process also led to significant production losses, prompting the need for a more reliable and efficient solution.
Strategic Automation
To address these issues, AQT collaborated with ABB to implement a robot production cell in its Hue plant. This cell includes an ABB IRB4600 industrial robot, an IRB2600 industrial robot, and a molding machine. The IRB4600 robot positions the quartz workpiece for heat treatment, while the IRB2600 robot ensures uniform heating of the piece. This systematic approach has minimized manual intervention and improved precision in the production process.
Enhanced Efficiency and Quality
Since the integration of ABB robots, AQT has witnessed a dramatic improvement in plant efficiency. The number of defective products due to production errors has decreased fivefold, and production cycle times have dropped from 25 minutes to just five minutes. The average daily output has increased to 100 pieces, a four-fold enhancement compared to the previous manual process. These advancements have resulted in consistent high-quality products and better working conditions for the employees.
Key Benefits of Automation
– Significant reduction in production errors
– Enhanced worker safety and reduced turnover
– Drastic reduction in production cycle times
– Four-fold increase in daily output
– Consistent high-quality products
America Quartz Technology’s decision to adopt ABB robotic solutions has led to substantial improvements in productivity, safety, and product quality. The use of these advanced robots has not only streamlined the manufacturing process but also positioned AQT as a leader in utilizing cutting-edge technology within the semiconductor industry. This success story underscores the transformative potential of automation in addressing labor shortages and enhancing operational efficiency. As AQT plans to invest in more robotic stations, the future of their production capabilities looks promising, setting a benchmark for other manufacturers to follow.
