Semiconductor industry Autonomous mobile robot assists in manufacturing

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A US chip manufacturer has optimized its material transport with the help of the self-navigating autonomous mobile robot LD from Omron. This robot was developed for dynamic material transport in challenging environments. Now, seven robots autonomously handle the material transport over long distances.

To be able to act with a vision for the future, companies are increasingly rationalizing their manufacturing and material flows. Transportation and logistics in the manufacturing sites are moving into focus here, as this can relieve employees and increase productivity. A good example is provided by the booming semiconductor industry. According to McKinsey, the global semiconductor industry can become a trillion-dollar sector by 2030. It is currently growing by six to eight percent annually.

Optimize one's own production processes

To support its expansion, the company Polar Semiconductor, a renowned manufacturer of semiconductor chips for the automotive and household appliance industries based in the heart of the US automotive industry, planned to optimize production processes, shorten transport routes within the plant, and increase workforce efficiency. The international robotics experts from Omron provided support for this project, helping the project team implement a flexible, precise, and cost-efficient solution.

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Robot works side by side with the employees

In the selection process, the choice fell on Omron's mobile robots LD 60/90, which have since been used side by side with the manufacturing staff. As in many other industries, the growing shortage of skilled workers currently poses immense challenges for the semiconductor industry. The use of mobile robots enables Polar employees to use their skills in a more targeted and efficient manner than before. Instead of having to deal with the transport of materials or products, they can focus on value-adding and more complex tasks. The LD is a self-navigating autonomous mobile robot (AMR) designed for dynamic material transportation in challenging environments. It is capable of maneuvering through narrow aisles and busy areas alongside employees.

Detailed simulation and mapping surveys

At the beginning of the project, the responsible parties at Polar Semiconductor created an overview of current processes, for example, how long materials were on the move within the manufacturing process. Throughout the entire product lifecycle, that was over 40 miles. In collaboration with Omron, the team then conducted detailed simulation and mapping surveys. This involved analyzing the entire facility and assessing the speed at which products could be transported through the production line. The results of the analyses provided valuable insights into the feasibility and benefits of utilizing AMRs, thus offering solid justifications for the investment.

The robots simplify workflows

Despite initial concerns about the new robot technology from the employees, the operators were quickly convinced of the benefits that the LD brings to their work: The robots simplified workflows and allowed focusing on important activities such as operating the plants while the robots ensured a continuous and timely material flow.

The solution includes a fleet of seven robots that efficiently transport materials from the main warehouse for unfinished goods in work-in-progress (WIP) status to various points in manufacturing. The robots autonomously handle material transport over long distances, significantly reducing manual interventions and improving the overall efficiency of the manufacturing process.

Throughout the entire setup phase, Omron provided the Polar team with advice and support. The experts offered rapid assistance when challenges arose. Their hands-on support and expertise ensured the successful implementation and continuous improvement of this project.

The biggest advantage I have identified is that we can make the robots maneuver more than humans could.

Darren Desmarais, Industrial Engineer at Polar

High appreciation among operators and engineers

Darren Desmarais, Industrial Engineer at Polar, explains the transformative effect of the solution: "With these robots, we can move Work-in-Progress (WIP) parts quicker and easier without operators having to leave the machine they are currently working on. The biggest advantage I've identified is that we can have the robots maneuver more than would be possible for humans."

The initial reluctance of operators and engineers towards the robots has evolved into high acceptance and appreciation. Through the seamless integration of the solution, users now enjoy interacting with the robots. Moreover, they appreciate the precise and timely delivery of various items to their respective tools. By eliminating thousands of kilometers that have to be covered within the plant each year, the operators save valuable time, thereby increasing productivity and efficiency.

With the help of the mobile robotic solution, Polar Semiconductor was able to successfully implement its goals of increasing productivity, optimizing workflows, and creating a leaner, more efficient manufacturing process.