Capacity improvement in HGA manufacturing of the Ultra4 product

Abstract

This study is performed in HGA (Head Gimbal Assembly) manufacturing processin part of assembly process line of Ultra4 product including front line which is assembly processand back end line which is concerned with mechanical inspection. This case study is to develop HGA manufacturing process and improve cell capacity of HGA manufacturing. The case study focuses on the critical operations of HGA assembly line that are the bottle-neck operation by reviewing from individual operation capacities and their UPH (Units perHour). There are totally three operations that are the critical operations for capacity constraint: Gimbal bond, Flex bond, and Tack tail operation. Motion and Time study is the most important role in improving the HGA manufacturing process. Motion study is used to analyze a given method in that operation and to help develop an efficient work. Its purpose is to eliminate or reduce ineffective movements and to facilitate and speed effective movements. Time study is often referred to a work measurement. It involves the technique of establishing an allowed time standard to perform a given task, based on measurement of the work content of the prescribed method, with allowance for fatigue and for personal and unavoidable delays. From studying, evaluation factors are also analyzed with suitable statistical tools. From improvement at those three operations, that leads to increase in cell capacity from 10,500 loaded units per day to 11,500 loaded units per day.