An island of automation is an automated assembly or test machine that is not fully integrated with other pre and post process assembly or test machines. Basically, these systems operate independently and are loaded, started, and unloaded manually. Operations typically assigns employees to feed them around the clock. In today's world of 24/7 always-on, you might think these islands no longer exist, but you would be wrong. Islands of automation continue to be created today for several reasons that I will explain.
Why do we see islands of automation?
Complex industrial processes require the integration of disciplines and technologies from multiple vendors into one or more machines. For example, it is common to have one station that handles the assembly, another machine for gluing, and a third that measures and dispenses fluids in preprogrammed ways. Companies often have a process with 10 or 20 major process steps, all with different operational goals. It is natural to first optimize within the operational boundaries of a given technical solution. Most early optimization efforts are focused on removing waste and inefficiencies within a modular boundary (machine). The end result of this common-sense approach is often a set of highly-optimized islands of automation.
Transportation between these islands is a common challenge
The next level of optimization is the creation and execution of a common island to island transportation system. These often require a lot of thought about universal part carrying methods (precision trays or enclosures) that can interface to the input and output areas of each island.
In the semiconductor industry, we see cleanroom transport systems, FOUPs which allow the wafers to be transferred between machines for processing or measurement.
Automated Material Handling Systems Solution (Semiconductor)
Self-Navigating Systems (SNS), also called Automatic Guided Vehicles (AGV), can autonomously move and handle highly sensitive payloads in semiconductor fabs. They play an essential role in flexible material handling to bridge the islands of automation.
The video below provides a 3d visualization a the SMT assembly line.
Many industries, like biotech, will develop similar transport systems like conveyors or automated guided vehicles (AGVs) to replace manual transport between stations. These automated handlers allow companies to add new capabilities, increase consistency and increase throughput.
How we look at the problem
Fusion builds a full view of the process by looking at the infrastructure path as well as the product path. We help teams understand the inputs and outputs of each step and evaluate the gaps. We recommend automated handlers or develop fixtures and jigs to automate previously manual processes like inspection, part handling, or assembly. We can determine the task time and measure transfer capability to optimize the whole process and solve the transport issue.
Fusion is good at looking across boundaries and finding ways to re-design the whole process to provide a better response to customers' needs.
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