I saw how Samsung’s robots make the Galaxy Z Fold 5

Twice a yr, Samsung brings journalists from all over the world to see their newest units at Galaxy Unpacked. The new telephones, foldables, tablets, smartwatches, and different units that Samsung unveils at Unpacked are the results of years of R&D that we, most of the people, aren’t aware of. When you cease to consider it, it’s really unbelievable how corporations like Samsung can pack a lot tech into a tool that matches into your pocket or sits in your wrist. That’s why when Samsung invited me to tour its so-called “Smart City” following the latest Unpacked occasion, I knew I couldn’t miss the possibility to see how they construct the Galaxy Z Fold 5 and Galaxy Z Flip 5.It’s not usually that we get an opportunity to tour the factories the place smartphone makers manufacture, assemble, and take a look at their units. I’ve solely completed it twice earlier than, as soon as with OPPO and later with Huawei, however each occasions had been earlier than the COVID-19 pandemic, so they might as nicely have occurred over a decade in the past in my thoughts. Plus, I wasn’t allowed to take any pictures or movies whereas on these excursions, and I’m nonetheless kicking myself for not taking detailed notes that I might look again on.This time, nonetheless, I got here higher ready. While I additionally wasn’t allowed to take any pictures or movies of Samsung’s manufacturing or meeting traces, I jotted down eight pages of notes within the Samsung Notes app utilizing the S Pen on my Z Fold 5 evaluate unit (which was possibly overkill, however I wanted an excuse to check the cellphone’s options out anyway). I additionally reached out to Samsung after the tour to get a few of the presentation supplies they confirmed us and a video exhibiting plenty of the manufacturing and meeting steps we noticed. Here’s a breakdown of the perfect elements of the tour.Disclaimer: Samsung coated my journey and meals bills for this journey. However, they didn’t ask me to write down this text nor did they’ve the chance to evaluate this text or provide any editorial enter earlier than its publication. I did seek the advice of extensively with fellow attendee Dylan Huynh, nonetheless, as he additionally attended the tour and extensively took notes of his personal.Gumi: The metropolis the place the magic beginsGumi is a metropolis positioned southeast of Seoul, and it’s one among South Korea’s main industrial facilities. Gumi is house to industrial complexes from actually hundreds of various corporations, however Samsung’s is among the many greatest within the space. Samsung has two main campuses right here, a number of dormitories, a hospital, a faculty, numerous welfare, health, and life-style facilities, and different buildings to accommodate the numerous staff that dwell and work within the metropolis. Collectively, Samsung refers to its Gumi operations as its “Smart City,” which is becoming given its measurement (~36 km²) and inhabitants (~14,000 staff).Image 1 of two(Image credit score: Dylan Huynh)(Image credit score: Dylan Huynh)Samsung’s Smart City, in fact, isn’t the one location the place the corporate assembles units, as they’ve meeting line hubs in Vietnam, India, Indonesia, Brazil, Turkey, and Egypt as nicely, however it’s the place they do plenty of R&D on easy methods to optimize the manufacturing and meeting of their newest units. Thanks to those refinements, the corporate has been capable of churn out over 6 billion smartphones to this point throughout all its factories worldwide.When you hear that determine, you may suppose that Samsung’s obtained all of it found out relating to automating smartphone manufacturing. While Samsung has automated plenty of its processes already and is engaged on automating much more, there are a number of steps that also require human involvement. But I’m getting forward of myself right here as a result of I wish to discuss a few of the cool issues Samsung teased us with earlier than we walked down the manufacturing and meeting traces.Samsung’s smartphone museumOur Smart City tour started with a stroll down reminiscence lane via Samsung’s smartphone museum, the place we noticed an exhibit of the important thing units Samsung made all through its a few years. We noticed units like the primary Galaxy S, the precursor to the primary Note (RIP), i.e., the Galaxy Edge, the primary Galaxy Fold, and so forth. (Image credit score: Mishaal Rahman)Better but was the showcase of each smartphone mannequin Samsung had ever made. Samsung crammed a room with glass instances that held one cellphone of every mannequin they made. We even obtained to see the restricted version Olympic-branded telephones Samsung made, in addition to the precise torch used to start out the 2018 Winter Olympics in PyeongChang. As a reporter who has been masking cellular tech for years, I knew that Samsung made plenty of telephones, however seeing actually each cellphone they ever made in a single room was actually one thing else.Okay, I lied: There was one cellphone lacking from the exhibit. I’m positive you already know which one it’s, however in case I have to spell it out, it was the Galaxy Note 7. I’m not stunned that Samsung principally pretends the Note 7 by no means existed, given the massive reputational hit they took by releasing that machine, however it was nonetheless amusing to see it scrubbed from existence not solely within the museum but in addition in different graphics that they had that confirmed the timeline of their flagship machine releases. (They did have the Galaxy Note FE on show, although.)After the smartphone museum tour, we entered a room the place we noticed cross-sections of the Galaxy Z Fold 5 and Galaxy Z Flip 5. Every half was separated and organized horizontally so we might see how the elements had been stacked on prime of each other. This was a precursor to the primary tour, the place we’d later get to see half-assembled prototypes of every cellphone the place the hinge mechanism was totally uncovered. Fun truth: the Galaxy Z Flip 5’s hinge really has extra elements in it than the Galaxy Z Fold 5’s (45 versus 41).Before we might enter the manufacturing line, Samsung slapped stickers over the cameras on all our telephones so we couldn’t take any pictures. These stickers can be marked as “void” when eliminated, so Samsung would simply be capable of inform if anybody tried to take away them, take pictures, then slap them again on. That’s why all pictures from this level onward come from Samsung itself.(Image credit score: Samsung)The first massive leg of our tour coated how Samsung carves a block of metallic like aluminum to make the mould used to mass produce a smartphone. This course of creates what’s known as an injection mould, and Samsung confirmed us how they used to solely be capable of make molds that would produce one cellphone at a time however ultimately created molds that would produce a number of.We additionally noticed the CNC (laptop numerical management) machines that Samsung designed to make these molds. They demonstrated the precision of their machining by carving out the phrase “Samsung” right into a block of aluminum; the etching was so high-quality that the phrase “Samsung” was not solely capable of come out of the block but in addition couldn’t be felt by hand when touching the metallic. Samsung mentioned every CNC machine had sensors that fed knowledge to a close-by knowledge middle for additional research and optimization.The molds used to supply Samsung’s telephones are carved with precision from a block of metallic.Samsung additionally confirmed off the completely different textured backs they examined, together with some that had been shiny and a few that had been matte. I actually preferred the texture of the completely different textures they experimented with, so I’m unhappy when a cellphone ships with a again that’s extra “safe,” i.e., it appeals to extra folks, is cheaper to make, and is boring sufficient that it may be used to upsell folks on different designs. Samsung does make a ton of various Galaxy telephones, although, so not each single mannequin can ship fancifully coloured matte backs by default.Speaking of coloration, Samsung repeatedly touted the way it was working to cut back the environmental influence of its manufacturing course of. They talked about how they recycled the aluminum scraps used to create molds so they might make extra of them, they usually additionally introduced up how they had been shifting away from petroleum-based dyes for his or her metallic backs in favor of extra natural dyes. Samsung says that natural dyes like cocoa, gardenia, and cochineal now comprise as much as 20% of the dyes they use for his or her units. (Image credit score: Samsung)Loads of the actually cool stuff we noticed throughout this a part of the tour got here both from issues Samsung confirmed us in a demo room off to the aspect or issues they mentioned or confirmed on screens, as we weren’t allowed to stroll previous a yellow line to get near the CNC equipment or the machines used to shine, blast, and wash the metallic blocks. This, nonetheless, was not a giant deal to me, as at this stage of the manufacturing course of, the metallic blocks solely barely resemble the design of a cellphone. You might discover issues like rectangular cutouts for digicam bumps, however that was it. Samsung even outright instructed us that they had been actively engaged on their subsequent Galaxy Fold, presumably known as the Galaxy Z Fold 6, right here as a result of there was nothing we’d be capable of discern anyway.Before we headed over to the primary meeting line, Samsung briefly confirmed us the realm the place the telephones’ PCBs (printed circuit boards) had been made. Using a floor mounting machine (SMD) course of, Samsung’s equipment quickly mounts and solders parts (about one each 0.047s) onto a big, dual-sided PCB that’s then lower into particular person boards for telephones. We weren’t capable of see the SMD course of up shut, nonetheless, because the equipment was contained inside a semi-clean room the place the temperature, humidity, and variety of mud particles had been always being measured.Because they had been so involved with mud particles coming into the semi-clean room, Samsung requested everybody to placed on a disposable shoe cowl earlier than we even peeked via the glass. Given how usually folks should put these shoe covers on, Samsung really had a machine that mechanically wraps the duvet round your shoe if you stick your foot in. And only for added safety, we needed to stroll over a bumpy a part of the ground to catch any stray mud particles that we might have stepped on earlier than coming into however after placing on the shoe cowl. We needed to hold these shoe covers on as we toured the following space, too. Putting all of it collectively, one step at a time(Image credit score: Samsung)After all the person parts, just like the chassis, SoC, show, battery, and so forth., are manufactured or introduced into the ability, it’s all put collectively in the primary meeting line. In the Gumi facility, there are a complete of 25 meeting traces, although solely 16 had been really in use on the time of our tour. Because of this further capability, Samsung is ready to act as a contract producer for different OEMs. But we had been there to see Samsung telephones being made, and that’s precisely what we noticed.Samsung guided us down the center of two meeting traces: To our left was a line that was assembling the Galaxy S23 Ultra for Verizon, and to our proper was a line for the Galaxy Z Fold 5. There was additionally a line for the Galaxy Z Flip 5, one line additional to our proper, however we weren’t allowed to stroll over to it. We did, nonetheless, get to see how supplies are transported across the room whereas we had been confined to our lane: Big robots known as AGVs (automated guided automobiles) patrol the ground on designated paths marked by silver traces.Samsung confirmed us two huge meeting traces the place it builds the Galaxy Z Fold 5 and Galaxy S23 Ultra.Each meeting line is very large, which is smart since there are such a lot of particular person parts that should be put collectively after which inspected. Many parts can solely be examined as soon as they’re added to the essential body of the machine because the motherboard must energy as much as load the testing instruments Samsung makes use of throughout meeting.One of the extra attention-grabbing assessments in the course of the meeting course of was the one for water resistance, which, opposite to what one may suppose, didn’t contain submerging the cellphone in water. Instead, the telephones had been inserted right into a chamber, and 15 kPA of air was pumped inside; if the sensor detected any growth after 20 seconds, then it failed the take a look at.Another attention-grabbing take a look at is the one which corrects for digicam parallax. A machine takes pictures of a particular sample with every rear digicam after which calibrates accordingly. Then there are chambers to check the varied radios, like WiFi, Bluetooth, Ultra-Wideband, and NFC (particularly, Samsung Pay). (Image credit score: Samsung)Given what number of parts there are, some are certain to fail inspection. Devices that fail a take a look at are ejected from the meeting line and positioned on a rack for a human employee to examine. This is seemingly uncommon, nonetheless, as Samsung instructed us in the course of the tour that the failure fee is barely 0.7%.The low failure fee will be attributed to the standard of elements, in fact, but in addition to how optimized and automatic the method has change into. As I discussed earlier than, although, Samsung has but to completely automate each step of the meeting course of. Notably, the final step, packing, has but to be automated. Samsung nonetheless depends on handbook labor to pack the assembled telephones into packing containers and apply labels to them.  However, Samsung is definitely working a pilot line that totally automates the whole meeting course of, which incorporates packing. The line that assembled the Verizon Galaxy S23 Ultra was really a part of this pilot program, whereas the road for the Galaxy Z Fold 5 nonetheless had staff manually making use of the display protector and packing the machine into packing containers (with the assistance of varied instruments and machines, in fact). Samsung instructed us that it’s working to completely automate the whole meeting course of by the top of this yr; it’s already automated 9/12 steps within the course of however continues to be engaged on automating the consumption and verification of supplies from distributors. It’s not over as soon as the telephones are assembled(Image credit score: Samsung)The assessments that Samsung’s robots run in the course of the meeting line are hardly consultant of real-world use, however that’s not the purpose. Those robots solely take a look at that the {hardware} works to specification. In their automation testing lab, Samsung places its telephones and smartwatches via a wide range of completely different situations to check numerous options and mimic real-world use. These embrace:Accelerated getting older: Samsung runs a script that repeatedly loops via numerous actions, like making a name, watching a video, and so forth., as a way to extrapolate how the cellphone may behave and carry out after years of use. Activity detection (swimming): Two smartwatches are positioned on the wrists of robotic arms that simulate a swimming movement. Bluetooth connections: A robotic always opens and closes the case of a pair of earbuds to quickly take a look at Bluetooth connection/disconnection habits. Fingerprint authentication: A robotic arm assessments the precision of under-display fingerprint scanners by repeatedly authenticating utilizing fingerprint knowledge from dozens of staff.GPS testing: A robotic strikes a cellphone barely in numerous instructions to check satellite tv for pc accuracy.  Neck stretch reminders: A pair of earbuds are inserted right into a robotic head as a way to set off neck stretch reminders. SmartThings integration: Samsung constructed a mini house of their lab full with mini curtains and lightweight bulbs subsequent to a full-size Samsung fridge and washer as a way to take a look at numerous SmartThings integrations and routines. Temperature variation: A Fold and Flip are positioned in a temperature-varying chamber and subjected to fixed folds and unfolds because the temperature is adjusted. Walking: A robotic holds a cellphone whereas barely vibrating and shifting forwards and backwards in a line to simulate a cellphone being held in your pocket. Image 1 of 3(Image credit score: Samsung)(Image credit score: Samsung)(Image credit score: Samsung)There had been a wide range of different automated assessments being run on this lab that I can’t bear in mind now, however I undoubtedly bear in mind strolling by a bunch of various benches the place PCs had been working numerous ADB instructions to automate button presses or app launches.Personally, the software program tie-in is what made the automation testing lab the spotlight of the tour for me, and I used to be unhappy that we weren’t capable of take any pictures or movies of it. Fortunately, the video that Samsung shared with us really reveals off plenty of what I noticed whereas touring the automation testing lab. Plus, this lab is definitely the place a few of the units that Samsung places up on its Remote Test Lab really come from, so holding that tidbit at the back of my thoughts will certainly jog my reminiscence about this go to.I hope I get the possibility to do one other manufacturing facility tour like this once more as a result of I undoubtedly discovered quite a bit throughout my go to to Samsung’s Smart City. My focus is extra on the software program aspect of issues in the event you haven’t seen, which is why plenty of what I noticed in Gumi was new and thrilling to me. There are nonetheless some particulars in regards to the tour that I couldn’t discover a approach to slot into this text, like how Samsung assessments its Ultra-Thin Glass for foldables and the way Samsung applied machine studying and distant work into their processes, however I’ve to finish this text someplace.I’ll go away you with one thing amusing, although: Samsung’s Bixby-powered Galaxy Home sensible audio system made an look throughout our tour. Samsung introduced these audio system method again in 2018, however they by no means really launched. These audio system had been inconspicuously positioned behind a desk in one of many demo rooms, although I don’t bear in mind in the event that they had been really getting used. So I actually did get to see each Galaxy product Samsung ever made apart from the Note 7.If you wish to try the total video Samsung despatched us of the meeting and testing of the Galaxy Z Fold 5 and Galaxy Z Flip 5, you possibly can see it right here.