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Process Challenges in the Hard Drive Industry
Adam Wray
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Cost under increasing pressure• Process Time• Cost of Ownership• CE Presence
Increased presence in CE sectorIncreased mix of Form Factors – no longer Niche for sub 2.5 inch (0.85, 1.0, 1.8)
• Process Capability and Flexibility• Cost vs Competing Technologies
HDD Industry DynamicsHDD Industry Dynamics
Continuing push on Areal Density• TPI increasing • BPI Increasing• Fly Height Decreasing
Transition to Perpendicular
Increasing Quality TargetsIncreased focus on DPPM and reliability for major integrators
• 1000 DPPM in ’03 with a target of < 200 DPPM in ‘06Existing Test Philosophies being challenged for CE sector
• Contradiction between low cost and increased environmental demand
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Technical Capability
Machine/ system Efficiency
Process capability
Quality Products
Time To Market
Competitive costs
Flexibility and agility
Growth capability
Xyratex Customer
Operational Efficiency and ScaleC
ollaboration
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HDD Process OverviewHDD Process Overview
Motor & Casting
Wafers
Head Fabrication
Substrate
Media Manufacturing
Burnish & Glide
Final Assembly
Head-DiskAssembly
PCB Assembly
Head Gimbal Assembly
HGA Test
Head-stack Assembly
Pack & Ship
Servo Track Writing
- Production Test
HDA
HDD
DiskHeadCertification
Production Test
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• ~ 2002
• Single Environment
• Water cooled system
● Range 25 → 70 ºC
● Accuracy ~ ± 2 ºC
• ~ 1998
•Shared Environment
• Air cooled system
● Range 35 → 55 ºC
● Accuracy ~ ± 5 C
• ~ 2006
• Single Environment
• Thermo Electric
Cooling (TEC)
● Range -10 → 85 ºC
● Accuracy ~ ± 1 ºC
Production Test - Thermal PerformanceProduction Test - Thermal Performance
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• ~2002
• Individual Hard mount
• Constrained layer springs
• Less Crosstalk
• System vibration effects becoming an issue for new drives
• 0.02 Rad/s/s @ 500Hz
• ~2005
• Individually isolated soft mounts
• Offset Pivot Technology
• Vibrationally Decoupled Fans
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•Servo-fill capable – in automated system
• 0.006 Rad/s/s @ 500Hz
Production Test - Vibration PerformanceProduction Test - Vibration Performance
• ~1998
• Hard coupled matrix of slots
• Hard ‘wedge’ mounted drives
• Crosstalk became an issue for new drives
• 0.09 Rad/s/s @ 500Hz
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Production ‘Test’ – Process EvolutionProduction ‘Test’ – Process Evolution
120 Drives >2000 Drives
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HDD Process Overview - ServowriteHDD Process Overview - Servowrite
Motor & Casting
Wafers
Head Fabrication
Substrate
Media Manufacturing
Burnish & Glide
Final Assembly
Head-DiskAssembly
PCB Assembly
Head Gimbal Assembly
HGA Test
Head-stack Assembly
Pack & Ship
Servo Track Writing
HDA
HDD
DiskHeadCertification
Production Test
Media Writing
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Servo Writer TechnologyServo Writer Technology
Printing
XyratexHi-Speed / Hi-Density
ServowriterCORE Technology
200MHz200MHz 400MHz400MHz
Disk Automation & Optics
Xyratex High Performance Conventional Servo Writer Systems
Media Writers
Self Servo / fill systems
Partnering
Customer IP
Customer IPXyratexHighly automated Production Rack
CORE Technology
Customer IP
Rack and media writer P
artnering
Partnering
600600--800MHz800MHz
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HDD Process Overview - Disk CertificationHDD Process Overview - Disk Certification
Motor & Casting
Wafers
Head Fabrication
Substrate
Media Manufacturing
Burnish & Glide
Final Assembly
Head-DiskAssembly
PCB Assembly
Head Gimbal Assembly
HGA Test
Head-stack Assembly
Pack & Ship
Servo Track Writing
Production Test
HDA
HDD
DiskHeadCertification
Xyratex Confidential
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Optical Certification – Xyratex SolutionOptical Certification – Xyratex Solution
Differential Scanning Fabry-Perot (DSF)
Based on standard Laser Technology
Non Contact Optical Probe
0.5 mm above surface
4 um spot size
20Mbit sampling rate
10,000 rpm
100% surface coverage in 40 seconds
Prototype Heads
Xyratex Confidential
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Optical Certification - ScratchOptical Certification - Scratch
Substrate Scratch
AFM Scan:
0.33 um wide
12.2 nm deep
Xyratex Scan
Small pre-sputter defects easily detected
Compromise between scan speed and defect resolution
Xyratex Confidential
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Optical Certification – Multiple Substrate PitsOptical Certification – Multiple Substrate Pits
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Optical Certification – Magnetic Surface DefectsOptical Certification – Magnetic Surface Defects
Xyratex Confidential
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Media Test Time TrendsMedia Test Time Trends
Media Certification Times
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10
20
30
40
50
60
70
80
90
100
110
120
2003 & Before 2004 2005 2006 Beyond
Test
Tim
e
Legacy Workcell
8 Spindles/WC
9+ sec. Avg. Cycle Time
Manual product feed
MGA Workcell
8 Spindles/WC
6.5 sec. Avg. Cycle Time
Automated product feed
XLTA
12 Spindles/WC
5.25 sec. Avg. Cycle Time
Manual product feed
X700
4-6 Spindles
4.5 – 5.0 sec. Avg. Cycle time
Manual product feed
Dedicated Automation
1 Spindle/WC
5 sec. Avg. Cycle Time
Automated product feed
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HDD Process Overview - Precision CleaningHDD Process Overview - Precision Cleaning
Motor & Casting
Wafers
Head Fabrication
Substrate
Media Manufacturing
Burnish & Glide
Final Assembly
Head-DiskAssembly
PCB Assembly
Head Gimbal Assembly
HGA Test
Head-stack Assembly
Pack & Ship
Servo Track Writing
Pre-sputter Clean
HDA
HDD
DiskHeadCertification
Production Test
Rough & Fine Polish Clean
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Production ‘Clean’ – Tool and Process EvolutionProduction ‘Clean’ – Tool and Process Evolution
240 DPH 2400 DPH
1985Single Standalone Scrub
2005Fully Automated Multi-module System
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• ~ 2000• Stainless Steel or PFA
•100 disk load
•4 Sided weir
• Frequency 132 KHz
• Power in- 1200 Watts
• ~ 2006• PFA
• 4-sided weir + QDR
• 100 disk load
• Frequency 950 KHz
• Power in 3600 Watts
Sonic CleanPerformance Trends and most advanced tanks configurationsSonic CleanPerformance Trends and most advanced tanks configurations
• 1994
•50 disk load•Stainless Steel
•3 sided weir
• Frequency 68 KHz
• Power in - 600 Watts
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Advanced Cascade Scrubbing – 2400 DPHAdvanced Cascade Scrubbing – 2400 DPH
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Example of equipment extendibilityExample of equipment extendibility
27mm
95mm
Media Manufacturing Requires Flexibility
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HDD Process OverviewHDD Process Overview
Motor & Casting
Wafers
Head Fabrication
Substrate
Media Manufacturing
Burnish & Glide
Final Assembly
Head-DiskAssembly
PCB Assembly
Head Gimbal Assembly
HGA Test
Head-stack Assembly
Pack & Ship
Servo Track Writing
Certification
Production Test
Certification
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Technical Capability
Machine / system Efficiency
Process capability
Quality Products
Time To Market
Competitive costs
Flexibility and agility
Growth capabilty
Xyratex Customer
Operational Efficiency
Collaboration
Ongoing Investment in R&DAnd Operational capability Customer Success
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Thank You
for your attention