In the exacting world of electronics and semiconductor manufacturing, precision is paramount. America Quartz Technology (AQT), a leading producer of formed quartz products, understands this better than most. At their state-of-the-art plant in Hue, Vietnam, even the slightest error or defect can have severe consequences, leading to costly production losses.

Until recently, AQT's manufacturing processes relied heavily on manual labor, with workers performing dangerous and repetitive high-temperature heating tasks. This not only posed significant safety risks but also contributed to high staff turnover, further compounding the challenges of maintaining consistent quality standards.

Recognizing the need for a transformative solution, AQT turned to ABB, a trusted automation partner with whom they had successfully collaborated at their U.S. facilities. The result is a groundbreaking robotic production cell that has reshaped AQT's operations, delivering unprecedented levels of efficiency, accuracy, and worker safety.

At the heart of this cutting-edge solution lies an impressive duo: the ABB IRB4600 industrial robot and the IRB2600 industrial robot, seamlessly integrated with a state-of-the-art molding machine. This robotic tandem performs a meticulously choreographed dance, streamlining AQT's intricate quartz processing workflow.

The process begins with the IRB4600 robot, which precisely picks up the quartz workpiece and positions it for the heat treatment phase. Next, the IRB2600 robot takes over, evenly heating the workpiece to exacting specifications. Once the heating is complete, a cylinder mechanism seamlessly sucks the heated quartz plate into the mold, where it is shaped to perfection. After a brief 30-second interval, the vacuum valve shuts off, and the IRB4600 robot retrieves the finished product, ready to embark on the next cycle.

The impact of this robotic solution on AQT's operations has been nothing short of transformative. Plant efficiency and performance have soared, with a remarkable five-fold reduction in defective products due to production errors. This remarkable achievement underscores the precision and consistency that robotic automation brings to the table.

"Using the solution provided by ABB, our products are now consistently completed to the highest quality, with less manual intervention required and a reduction in errors," said Tran Phuoc Thanh Vu, factory manager at America Quartz Technology. "Conditions have also improved for workers, as all of the dangerous and repetitive work is now taken care of by the robots."

But the benefits don't stop there. ABB's robotic solution has also facilitated a dramatic reduction in production cycle times. What once took 25 minutes now takes a mere five minutes, resulting in an average daily output of 100 pieces – a remarkable four-fold increase compared to the previous manual production process.

"The solution brings enormous value to the plant – it improves production capacity, ensures on-time delivery of customer orders, and offers high stability during the production process," Vu added. "We always aim to have a modern and professional factory, using the latest techniques and technologies to achieve a lean production process and improve productivity. Our good experience with ABB robots means that we plan to invest in several robot stations for the plant in the coming year."

As AQT continues to push the boundaries of precision manufacturing, their partnership with ABB has proven to be a game-changer. By harnessing the power of robotic automation, the company has not only enhanced its operational efficiency and quality standards but has also prioritized worker safety and well-being – a testament to the transformative potential of cutting-edge technology when applied thoughtfully and strategically.

In an industry where precision is paramount, AQT's robotic quartz production cell stands as a shining example of how innovation can drive sustainable competitive advantage while setting new benchmarks for excellence.