Application of Computer Integrated

Manufacturing in Hard Disc Drive

Industry*
By: Dennis McInerney
Submitted: December 4, 2000

Submitted for Advanced System Designs (IEM5303), MSETM

Professor Dr. John Nazemetz
Oklahoma State University

*Seagate Technologies, LLC

Oklahoma City Operations

Table of Contents
KEYWORDS......................................................................................................................3

ABSTRACT........................................................................................................................3
BACKGROUND................................................................................................................3
ABOUT SEAGATE TECHNOLOGY, LLC............................................................................3
COMPONENTS OF A DISC DRIVE....................................................................................4
CIM APPLICATIONS.......................................................................................................5
QUALITY FUNCTION DEPLOYMENT (QFD).....................................................................5
DESIGN FOR MANUFACTURING (DFM)..........................................................................5
AUTOMATED DISC DRIVE ASSEMBLY PROCESS..............................................................7
Complete Disc Drive Assembly Process.......................................................................7
Drive Assemble Process................................................................................................7
Robotics........................................................................................................................9
Barcoding....................................................................................................................10
Computer Integration..................................................................................................11
AUTOMATED STORAGE AND RETRIEVAL SYSTEM..........................................................12
AS/RS in Finished Goods............................................................................................12
Horizontal Carousels in Repair (Product Disposal Phase)........................................13
SUMMARY......................................................................................................................14
BIBLIOGRAPHY............................................................................................................15

List of Figures
Figure 1: A fully assembled hard disc drive with the topcover removedError: Reference
source not found
Figure 2 QFD for New product....................................Error: Reference source not found
Figure 3: Complete Disc Drive Assembly Process.....Error: Reference source not found
Figure 4 Detail of Drive Assembly................................Error: Reference source not found
Figure 5: Drive Assembly Line Computer Topology....Error: Reference source not found
Figure 6: Repair Finished Goods, Reynosa....................................................................13

List of Tables
Table 1 : Excerpts from Head Stack Assembly DFM Guide...............................................6
Table 2: Detail Explanation of HDD Assembly..................................................................8
Table 3: Detail Explanation of HDD Assembly..................................................................9
Table 4: Video Demonstration of Robotics in Drive Assemble..........................................9

KEYWORDS
Computer Integrated Manufacturing, CIM, Disc Drives, Quality Function Deployment,
QFD, Design for Manufacturing, DFM, Robotics, Conveyors, Barcodes, Automated
Storage and Retrieval System, ASRS.

ABSTRACT
The following white paper describes various computer-integrated manufacturing,
CIM, concepts as applied to the assembly of hard disc drives for personal and enterprise
computer systems. Unlike some white papers that delve into details on a specific CIM
concept, this paper will describe the general application of numerous CIM concepts
sprinkled throughout the hard disc drive product life cycle. The various CIM concepts to
be described are quality function deployment (QFD), design for manufacturing(DFM),
assembly automation, and automated storage and retrieval system (ASRS).

BACKGROUND
About Seagate Technology, LLC.
Seagate Technology is the worlds largest manufacturer of computer disc drives,
magnetic discs and read-write heads. Seagate competes in a market that requires nine
month product life cycles, one percent price erosion per week, customer expectation for
increased reliability and functionality, and delivery on demand (a pull system). The disc
drive industry can be classified as high volume low variety (H-L) industry as defined by
Singh.1 In order to better understand this high volume industry, the following is a list of
metrics that quantify the average volume per line, floor space capacity, people per line,
quality level as expressed as a yield, and line utilization2:

Average volume per day per line

1400-4300 units per line

Floor space capacity

4-10 units per ft2

People per line

Yield

Line utilization

6-11
97%
88-92% Uptime

Given the thousand of drives needed per day with limited people and factory square
footage, it should be apparent to stay in business for this industry the use of CIM concepts
is a necessity.

Components of a Disc Drive

To understand the CIM concepts to be presented, it is necessary to know the major
components of a current hard disc drive, HDD. For the purpose of this paper, an HDD
can be simplified into six major subassemblies. Below is a list of their names, acronyms,
and their functions for the hard disc drive:
1.

Basedeck, BSD, holds all the components and is designed for shock
and vibration resistance.

2.

Head Stack Assembly, HSA, provides the read and write capability

3.

Head Disc Assembly, HDA, provides the media to store data

4.

Motor, MTR, provides the rotation (currently 7200 to 15,000 rpm) for
the HDA

5.

Voice Coil Motor, VCM, provides the bridge and conversion of analog
signals to digital signals to be used by the computer.

6.

Topcover, TCV, provides an air tight seal to prevent contamination

from entering the basedeck and above components.3

1. Basedeck Basedeck

3. Head Disc Assembly

The above stated major

subassemblies are also shown in
Figure 1: A fully assembled hard
disc drive with the topcover
removed.
With the understanding of these

4. Motor (hidden
major components, various CIM
under HDA)
Figure
1:
A
fully
assembled
hard
disc
drive
with
the
topcover
concepts will be presented in
2. Head Stack Assembly
removed
order of a generic products
6. Top cover
lifecycle, specifically the design
(not pictured)
5. Voice Coil Motor
phase, production phase, and
then disposal phase.

CIM Applications
Quality Function Deployment (QFD)

Although the best use of quality function deployment is in the concept stage of a
products lifecycle, Seagate uses this technique with next generation products. Seagates
customers, in this case the Original Equipment Manufacturers (OEMs), usually have the
same requirements as the previous generation design, but often the importance of these
requirements change due to market demands. The QFD is used in the design phase to
weight where design engineering effort should be focused. This effort involves research
and testing of various new technologies and ultimately mathematical functions describing
the new technology feasibility with current technologies. These complex mathematical
functions are used for system (hard disc drive) predictability before prototypes are built.
Figure 2: QFD for Cheetah 73ES exemplifies the use a QFD for a new product.
QFD Product Planning Matrix
Product: Cheetah 73ES
Quality Function Deployment (QFD)

WHATs / Outputs
(CTQ's)

9 = Strong Relationship

Target

3 = Moderate Relationship

Minimize

1 = Weak Relationship

K a n o C la s s ific a tio n
Im p o rta n c e
C ritic a l C h a in
M TBF
AFR
TPI
BPI
P ro d u c t C o s t
Io m e te r
PP
W in b e n c h H E
W in b e n c h B u s
S e e k T im e
S p in d le S p e e d
E rro r R a te
CSS
IC B M S u p p o rt
R e d s to n e L S I
R e a d y T im e < = 7 s
Id le A c o u s tic s < = 3 .3 b e ls
S e e k A c o u s tic s < = 3 .6 b e ls
C a c h e S iz e
P o w e r C o n s u m p tio n
M a n u fa c tu ra b ility
EM I
CSA, VD E, EC , UL,

HOWs / Inputs
(Objective
Measures)

Legend Maximize

Direction of Improvement

BIC Performance

MB

TTM Schedule

MB 10

BIC Price

MB

High Reliability

MB

Meet Gov/Agency standards

MB 10

Minimum Capacity

MB 10

Ultra 320 I/F

MB 10

Quiet Operation

Operating Environment

Storage/Transportation Env.

3
9
9

3
3

3
9

9
9
9

9
3

Figure 2: QFD for New Product

Design For Manufacturing (DFM)

Design for manufacturing at Seagate is applied to each of the major subassemblies
mentioned in the Components of a Disc Drive section as well as their respective
fabrication and assembly processes. Not only is DFM used to aid the assembly processes,
but designers also take into consideration the software testing and packaging processes.
The use of design for manufacturing is evident through the use of smart engineering
software such as IDEAS and SABER, and also less sophisticated forms such as written
documents, known as DFM guides. Some examples of design for manufacturing that are
embedded in software expert systems are:

Common disc clamp method

Common Head Stack Assembly mounting method

Common tooling points (for each platform, 3.5-2.5)

Minimum screw types and size

Some Self locating parts, both use of symmetry and asymmetry

Common label type and placement

The above examples illustrate design commonalities that are embeded in the designers
software, knowledge base. But for the DFM features that are not automated (yet),
designers must refer to written documents. An example of a DFM document at Seagate
takes the form of a guide. Below are a few excerpts from Head Stack Assembly DFM
Guide4:
Table 1 : Excerpts from Head Stack Assembly DFM Guide
5.0
5.2
5.10
5.20
7.0
7.1

9.0
9.7

Required Design Features Essentials

Critical assembly mechanical specifications to
be specified using drive datum points such as
bearing shaft datum, actuator stop datum, etc.
Tolerance ring design minimum clearance
between OD of bearing cartridge and Eblock
bore ID to be .0035.
Design should not allow interposer to be
installed in reverse polarity condition

Comments

This cannot be designed in, but

needs to be verified by the coil
supplier as correctly connected.

Voice Coil Essentials

The physical track layout must include 4
cylinders outside the user area that are
reserved exclusively for use in the
manufacturing test process
Bearing cartridge Design and Attachment
Bearing cartridge shaft and housing should be
stainless steel

The above examples illustrate the use of design for manufacturing in the hard disc
assembly and subassembly processes. Other similar design documents exist that attempt
to standardized the testing and packaging of a fully assembled HDD.
Automated Disc Drive Assembly Process
Complete Disc Drive Assembly Process

There are over a thousand tasks required for design, development, production, and
testing of a computer disc drive, however, the focus of this paper is to explain in some
detail CIM applications in a couple of processes.
The disc drive assembly process can be described by five major events that must take
place. These events are titled Sub Assemble, Drive PCBA Install, Drive Test, and Final
Pack. A simple flow chart of the disc drive assembly process is depicted in Figure 3:
Complete Disc Drive Assembly.
SUB
SUB
ASSEMBLE
ASSEMBLE

DRIVE
DRIVE
ASSEMBLE
ASSEMBLE

PCBA
PCBA
INSTALL
INSTALL

DRIVE
DRIVE
TEST
TEST

FINAL
FINAL
PACK
PACK

Figure 3: Complete Disc Drive Assembly

Process
The Sub Assemble describes the activities needed to produce the subassemblies from
supplier components. The Drive Assemble process, to be described in further detail, is the
assembly of all the Sub Assemblies and other components to complete the hardware of a
disc drive. The PCBA Install is the installation of the printed circuit board assembly to the
drive assembly and the downloading of the appropriate firmware. Drive Test is a series of
test required to test software, firmware, and testing the hardware and software together as
a complete disc drive. Final Pack is the sorting, packaging, boxing, and storing of the hard
disc drive. Again, the focus of this paper is to describe in detail the CIM applications in the
Drive Assemble and the Final Pack processes.
Drive Assemble Process

DRIVE
DRIVE
ASSEMBLE
ASSEMBLE

To further understand the automation used for the Drive Assemble process depicted in
figure 2, a more detailed explanation of this assembly process will be described.

LOAD

16

Drive
Unload
to Test

Breather
Filter
Install

15

Top
Cover
Install

Motor
Install

Lower
Magnet
Install

As shown pictorially in Figure 4: Detail of Drive Assembly, this

assembly process consists of sixteen major tasks performed on
separate modular machines connected by an oval shaped
continuous conveyor layout located in a class 100 clean room. A
class 100 clean room refers to a self contained room capable of

providing on average only 100 parts per million of contamination of

a certain size.
A brief explanation of these tasks is described below in table

14

Upper
Magnet
Install

2, Detail Explanation of HDD Assembly:

Table 2: Detail Explanation of HDD Assembly

Step Step Name

1
Load

Breather

pallets with a basedeck.

Robotic operation that picks and

Filter Install
Motor Install

places a filter in the basedeck

Robotic operation that picks, places,

Lower

and screws motor in basedeck.

Robotic operation that picks and

Magnet

places lower half of magnet in

install
Media Stack

basedeck.
Robotic operation that picks, places,

media and spacer on top of motor

6

spindle.
Spacer Install Robotic operation that picks, places,
and secures top spacer on head stack

7
8

Disk Bias
Clamp Install

assembly.
Robotic that ?????
Robotic operation that picks, places,

Balance

and secures motor in basedeck.

Robotic operation that picks, places,

10

Measure
Balance

and screws motor in basedeck.

Robotic operation that picks, places,

11

Correct
Head Stack

and screws motor in basedeck.

Robotic operation that picks, places,

12

Install
Flex Screw

and screws motor in basedeck.

Robotic operation that picks, places,

Spacer
Install

Disk
Bias

Clamp
Install

Merge

Step Description
This is a manual operation defined as
the barcoding of pallets and loading the

13

Media
Stack

12

Flex
Screw
Install

11

Head
Stack
Install

Balance
Balance
10
9
Figure Correct
4: Detail of Drive
Assembly
Measure

13

Install
Merge

and screws motor in basedeck.

Robotic operation that picks, places,

14

Upper

and screws motor in basedeck.

Robotic operation that picks, places,

magnet

and screws motor in basedeck.

15

Install
Top cover

Robotic operation that picks, places,

16

Install
Unload

and screws motor in basedeck.

This is a manual operation defined as

Assembly.

removal of HDD from pallet, HDD

Route to

placed on conveyor going to test, and

Test.

pallet put in queue for reuse.

Table 3: Detail Explanation of HDD Assembly

The above steps are automated with the exception of step 1 and 16 which are manual
operations. The next sections will describe the automated steps in more detail.
Robotics
All robotics used in the above HDD assembly process are custom built from piece
parts, like an erector set, by Seagate engineers and technicians. Thus for proprietary
reasons, technical details cannot be written about the type, code used, etc. However, to
get an appreciation of the robotic movement on a HDD line embedded in the Table 4:
Video Demonstration of Robotics in Drive Assemble, are three video clips of the various
steps described above in Table 3: Detail Explanation of HDD Assembly.
Table 4: Video Demonstration of Robotics in Drive Assemble

Steps

Step Description and brief video description

5 - 10

Media and spacer stack, clamp install, balance measure,

and balance correct. This video was filmed during
engineering beta testing. Editorial: There is some human
involvement but those tasks are now currently automated.

15

Video Title
"Balance Measure
Clip.avi"

Top cover install. Again, this video is an engineering beta

test run.
"Example Top Cover
Install 9-29-99.avi"

15

Top cover screw. Again, , this video is an engineering beta

test run.
"Example
Screwdriver 9-29-99.avi"

Barcoding
An important aspect to the above automated assembly process is step 1, the initial
barcode attachment to the pallet and subsequent loading of the basedeck positioned in the
pallet. This barcode is used throughout the assembly process by each machine station. As
the pallet is positioned at each modular station, the station will read what configuration of
hard disc drive is needed. Currently, there are over 245 different hard disc drive
configurations. These configurations involve the numerous combinations of motors,
media, VCMs, and labels. Each HDD line has its own host computer that is constantly
sending and receiving information from the machine stations. When a station reads the
barcode, this information is sent to the host computer, where the host computer performs
error checking, configuration details, and sends correct configuration details to the
stations. Because a line can handle the multiple configurations given any batch size, this
automated line may be considered a flexible manufacturing system, FMS. However, the
line is constrained to only one media size (2.5 discs, or 3 discs), thus it could be argued
this is a mass production line.
Interestingly, step 1 involves the application of the barcode using human control. Like the
space shuttle which allows the astronauts to control the landing gear activation, For
deployment of the landing gear, the uplock hook for each gear is activated by the flight
crew initiating a gear-down command. 5, and so it is with the barcode label. Because
the planning and scheduling is not fully integrated with computer systems, what jobs to
run at this time cannot be trusted by automation. Thus, human intervention is still
necessary to handle the sudden and frequent schedule changes. Fortunately, a corporate
initiative is underway which will automate this part of the process within a year.
Computer Integration

As mentioned above, each line has a host computer that performs many functions.
The functions the host computer performs are product information, station monitoring and
control, and business data collection and storage. A simplified topology of the computer
architecture is displayed in Figure 5: Drive Assembly Line Computer Topology. As
mentioned previously, the host computer holds all disc drive configurations needed by a
station for all products. Thus the

Business
Server 2

Business
Server 1

station reads the barcode on a pallet

and sends this data to the host

Server

computer. The host computer will

Server

Ethernet

check this information and send a

message back to the station if it has the
appropriate resources needed to

Host
Line 1

perform its operation. If there is a

discrepancy the host computer will

Hub 1

stop the line. Some reasons for line

type of station bin material (labels,

the stations have the correct product

configurations such as media, HGAs,
and HSAs the host computer is also

16

Drive
Unload
to Test

Breather
Filter
Install

16

15

Top
Cover
Install

Motor
Install

15

Lower
Magnet
Install

14

13

Examples of sensors that are monitored

are part counters, pressure switches,

Upper
Magnet
Install

Media
Stack

Spacer
Install

Disk
Bias

Merge

12

Flex
Screw
Install

11

Head
Stack
Install

Clamp
Install

10

Balance
Correct

Balance
Measure

monitoring numerous sensors at the

stations and conveyor system.

Line 2

LOAD

screws, motors, etc.), and station

sensor disparities. While making sure

Hub 2

Line 1

stoppage are station bin refills (e.g.

labels, screws, motors, etc.), incorrect

Host
Line 2

14

LOAD

Drive
Unload
to Test

Breather
Filter
Install

Top
Cover
Install

Motor
Install

Lower
Magnet
Install

Upper
Magnet
Install

Media
Stack

Spacer
Install

Disk
Bias

13

Merge

12

Flex
Screw
Install

11

Head
Stack
Install

Clamp
Install

10

Balance
Correct

Balance
Measure

Figure 5: Drive Assembly Line Computer Topology

infrared proximity sensors, robot sensors, and

many others. 6 One important reason for this sensor monitoring is the ability to predict
scheduled or unscheduled maintenance. As stated earlier each station is modular and
mobile so it can be taken offline, pulled from the conveyor system and replaced with a
similar station. Depending on the station, this station swap out can take as little as five
minutes (i.e. Step 4) to two hours (i.e. Step 9 and 10). 7 Finally, another task for the host
computer is to collect production data for business databases. The host computer collects

and populates many databases with information such as raw material supply, refill levels of
station bins, disc drive lot quantity, serial numbers for major subassemblies and assembled
disc drive, date and time stamps for station activities and assembled disc drives, and sensor
data as mentioned previously. This data is uploaded to various corporate databases for
use by the many business functions such as purchasing, manufacturing engineering, plant
maintenance, supplier quality, production management, and design engineering.
Automated Storage and Retrieval System
AS/RS in Finished Goods

FINAL
FINAL
PACK
PACK

The majority of Seagate products are bought by OEMs using pull systems, thus
Seagate acts as a distributor. In other words, Seagate can be thought of as warehouse for
the OEMs. Given this business fact, the high volume factories are equipped with an
automated item storage and retrieval system. This ASRS system is shared by both
incoming (receiving) and shipping (finished goods). This system is a single command
cycle with 18 aisles and seven stories tall. There is a robotic picker for each aisle. An
interesting application of this ASRS is its multi story use. The receiving department is on
the first floor and supplies the various production lines, which reside on the floors above.
The production lines use the ASRS for incoming material but ultimately use this same
ASRS for finished goods. The use of the ASRS in receiving and finished goods provides
many benefits beyond traditional costs in labor reduction and efficiency. For the disc drive
industry, material handling damage is a serious and costly concern. Material handling
damage for disc drives comes in two forms, vibrational shock and electrostatic discharge
(ESD). The ASRS minimizes these two failure modes. First the use of the automated
picker assures constant velocity and careful placement. Second, the picker is always
electrically grounded from static electricity. Another benefit of using the ASRS in finished
goods is the inventory control feature. As stated earlier, Seagate factories are warehouses
and customers pull various quantities of products at any time. Thus, from the customers
viewpoint there must be an element of flexibility with regards to product configurations
and counts, but from a distributors viewpoint there must be accurate inventory control for
billing purposes.

Horizontal Carousels in Repair (Product Disposal Phase)

The last CIM application to discuss is again focused on material handling.
However, unlike the ASRS above, this material handling system is applied to the disposal
stage of the product. In Mexico, Seagate has a repair facility. The purpose repair is to
diagnose if a drive can be repaired and then make it configurable like new. However,
drives that cannot be repaired are scrapped. A material handling system is in use for the
finished goods of repaired drives. This system is integrates horizontal carousels,
conveyors, and light bars. A floor layout of this system is shown in Figure 6: Repair
Finished Goods, Reynosa.
Drives that are repaired are
barcoded into one of three
storage areas: 1. Horizontal

To
Packaging
via
Conveyor

Horizontal
Carousels
with Light
Bars

carousels, 2. Pull racks with

Material
Flow

light bars, or 3. Pull racks.

the barcode reader, the
computer displays to the
operator where to store the
item. The most frequently
ordered drives (for any given
week) are placed in area 2,
then area 1, and finally area 3.

C
o
n
v
e
y
o
r

When a drive is scanned by

Pull
Racks
with
Light
Display

Furthermore, the software is programmed to

Incoming
Repaired
Drives
Pull
Racks

Figure 6: Repair Finished Goods, Reynosa

place the most requested drives in arms reach, and less frequent drives higher up on the
racks. This system is also designed to streamline the packaging process. A packager can
prepare sixteen orders at once. With the use of sixteen empty tote boxes each staged on
the conveyor with a light in front of each box, the packager with the aid of a display and
lights on the racks can fill sixteen orders simultaneously. The packager watches a display
that shows quantities needed of a certain product. The computer will turn on lights in
front of the tote boxes needed for this specific product and count. Next the computer will
light the pull rack location where this product is located. If the product is not located in
the area 2 bins, then the carousel will begin to rotate and light the appropriate level where
the product is to be picked. If no lights appear, area 3 will have a flashing red light

indicating to the packager a manual search and pick must be made. Recall area 3 occurs
very infrequently (e.g. every two weeks).

SUMMARY
This paper described in some detail various computer-integrated manufacturing,
CIM, concepts as applied to the assembly of hard disc drives. This paper attempted to
show CIM concepts span the product life cycle, at least from design to disposal.
Furthermore, this paper attempted to show non-technical applications like QFD and DFM
guides, and the more traditional and technical CIM concepts such as automated assembly
and ASRS. Seagate Technologies is always investing in process improvements in all its
business like design engineering, factories, and warehouses. An example of this
commitment is a second generation automated disc drive assembly process that starts from
the subassemblies and ends with the ASRS. This initiative is expected to deliver 50 million
drives per quarter by creating a line that can produce a disc drive in 3.5 seconds. This
second generation line will also deliver 20,000 disc drives per day per line, 94% line
uptime, zero operators per line, and 99.5% yields. In order to reach these lofty goals
Seagate management, engineers, and technicians are applying CIM concepts such as
barcoding, high speed conveyors, and complete system integration using computer
networking and business data warehouses.

BIBLIOGRAPHY

Nanua Singh, Computer -Integrated Design and Manufacturing, John Wiley & Sons, Inc., New
York, 1996., p. 532
1

Tom Metzner, Advanced Manufacturing Report, Internal Seagate presentation, Seagate

Technologies, LLC., Singapore, 1999.
2

Disk Drive Technology Course, KnowledgeTek, Broomfield Colorado, 1999., p. 3-25.

Head Stack Assembly Design For Manufacturing Guide, Internal Seagate Manufacturing Guide,
Rev 3.1
Hydraulic System: Landing Gear System, www.science.ksc.nasa.gov/shuttle/technology/stsnewsref/sts-gear.html
5

Tom Metzner, Seagate Technologies, LLC Oklahoma City Operations, Personal Interview, November
2000.
6

Jeremy Guest, Seagate Technologies, LLC Oklahoma City Operations, Personal Interview, November
2000.
7