Twice a 12 months, Samsung brings journalists from around the globe to see their newest units at Galaxy Unpacked. The brand 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 about. Whenever you cease to consider it, it’s really unimaginable how firms 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 “Good Metropolis” following the most up-to-date Unpacked occasion, I knew I couldn’t miss the prospect to see how they construct the Galaxy Z Fold 5 and Galaxy Z Flip 5.
It’s not typically that we get an opportunity to tour the factories the place smartphone makers manufacture, assemble, and check their units. I’ve solely carried out it twice earlier than, as soon as with OPPO and later with Huawei, however each occasions have been earlier than the COVID-19 pandemic, so they might as effectively 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 may look again on.
This time, nonetheless, I got here higher ready. Whereas I additionally wasn’t allowed to take any pictures or movies of Samsung’s manufacturing or meeting strains, I jotted down eight pages of notes within the Samsung Notes app utilizing the S Pen on my Z Fold 5 overview 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 number of the presentation supplies they confirmed us and a video displaying numerous the manufacturing and meeting steps we noticed. Right here’s a breakdown of one of the best elements of the tour.
Disclaimer: Samsung lined my journey and meals bills for this journey. Nonetheless, they didn’t ask me to jot down this text nor did they’ve the chance to overview 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 town the place the magic begins
Gumi is a metropolis situated southeast of Seoul, and it’s one in all South Korea’s main industrial facilities. Gumi is residence to industrial complexes from actually hundreds of various firms, 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 college, varied welfare, health, and way of life facilities, and different buildings to accommodate the various staff that reside and work within the metropolis. Collectively, Samsung refers to its Gumi operations as its “Good Metropolis,” which is becoming given its dimension (~36 km²) and inhabitants (~14,000 staff).
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Samsung’s Good Metropolis, after all, 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 effectively, but it surely’s the place they do numerous R&D on find out how to optimize the manufacturing and meeting of their newest units. Thanks to those refinements, the corporate has been in a position to churn out over 6 billion smartphones so far throughout all its factories worldwide.
Whenever you hear that determine, you may suppose that Samsung’s acquired all of it discovered with regards to automating smartphone manufacturing. Whereas Samsung has automated numerous its processes already and is engaged on automating much more, there are a number of steps that also require human involvement. However I’m getting forward of myself right here as a result of I need to speak about a number of the cool issues Samsung teased us with earlier than we walked down the manufacturing and meeting strains.
Samsung’s smartphone museum
Our Good Metropolis tour started with a stroll down reminiscence lane by way of 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 Word (RIP), i.e., the Galaxy Edge, the primary Galaxy Fold, and so forth.
Higher but was the showcase of each smartphone mannequin Samsung had ever made. Samsung stuffed a room with glass instances that held one cellphone of every mannequin they made. We even acquired to see the restricted version Olympic-branded cellphones Samsung made, in addition to the precise torch used to start out the 2018 Winter Olympics in PyeongChang. As a reporter who has been protecting cellular tech for years, I knew that Samsung made a lot 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 certain you already know which one it’s, however in case I have to spell it out, it was the Galaxy Word 7. I’m not shocked that Samsung principally pretends the Word 7 by no means existed, given the large reputational hit they took by releasing that machine, but it surely 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 Word 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. Each half was separated and organized horizontally so we may see how the elements have been stacked on prime of each other. This was a precursor to the principle tour, the place we’d later get to see half-assembled prototypes of every cellphone the place the hinge mechanism was absolutely uncovered. Enjoyable truth: the Galaxy Z Flip 5’s hinge really has extra elements in it than the Galaxy Z Fold 5’s (45 versus 41).
Earlier than we may enter the manufacturing line, Samsung slapped stickers over the cameras on all our telephones so we couldn’t take any pictures. These stickers could be marked as “void” when eliminated, so Samsung would simply have the ability to inform if anybody tried to take away them, take pictures, then slap them again on. That’s why all photos from this level onward come from Samsung itself.
The primary massive leg of our tour lined how Samsung carves a block of steel like aluminum to make the mildew used to mass produce a smartphone. This course of creates what’s known as an injection mildew, and Samsung confirmed us how they used to solely have the ability to make molds that might produce one cellphone at a time however finally created molds that might 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 positive that the phrase “Samsung” was not solely in a position to come out of the block but in addition couldn’t be felt by hand when touching the steel. Samsung mentioned every CNC machine had sensors that fed knowledge to a close-by knowledge heart for additional research and optimization.
The molds used to provide Samsung’s telephones are carved with precision from a block of steel.
Samsung additionally confirmed off the totally different textured backs they examined, together with some that have been shiny and a few that have been matte. I actually appreciated the texture of the totally different textures they experimented with, so I’m unhappy when a cellphone ships with a again that’s extra “protected,” 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.
Talking of shade, 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 may make extra of them, they usually additionally introduced up how they have been transferring away from petroleum-based dyes for his or her steel 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.
Lots 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 steel blocks. This, nonetheless, was not a giant deal to me, as at this stage of the manufacturing course of, the steel blocks solely barely resemble the design of a cellphone. You may discover issues like rectangular cutouts for digicam bumps, however that was it. Samsung even outright informed us that they have 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 have the ability to discern anyway.
Earlier than we headed over to the principle meeting line, Samsung briefly confirmed us the realm the place the telephones’ PCBs (printed circuit boards) have been made. Utilizing a floor mounting machine (SMD) course of, Samsung’s equipment quickly mounts and solders elements (about one each 0.047s) onto a big, dual-sided PCB that’s then minimize into particular person boards for telephones. We weren’t in a position to 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 have been continuously being measured.
As a result of they have 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 by way of the glass. Given how typically folks should put these shoe covers on, Samsung really had a machine that robotically wraps the quilt round your shoe while 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 subsequent space, too.
Placing all of it collectively, one step at a time
In any case the person elements, just like the chassis, SoC, show, battery, and many others., are manufactured or introduced into the ability, it’s all put collectively in the principle meeting line. Within the Gumi facility, there are a complete of 25 meeting strains, although solely 16 have been really in use on the time of our tour. Due to this additional capability, Samsung is ready to act as a contract producer for different OEMs. However we have been there to see Samsung telephones being made, and that’s precisely what we noticed.
Samsung guided us down the center of two meeting strains: To our left was a line that was assembling the Galaxy S23 Extremely 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 have been confined to our lane: Large robots known as AGVs (automated guided autos) patrol the ground on designated paths marked by silver strains.
Samsung confirmed us two huge meeting strains the place it builds the Galaxy Z Fold 5 and Galaxy S23 Extremely.
Every meeting line is huge, which is sensible since there are such a lot of particular person elements that must be put collectively after which inspected. Many elements can solely be examined as soon as they’re added to the fundamental body of the machine because the motherboard must energy as much as load the testing instruments Samsung makes use of throughout meeting.
One of many extra fascinating checks throughout 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. As an alternative, the telephones have been inserted right into a chamber, and 15 kPA of air was pumped inside; if the sensor detected any enlargement after 20 seconds, then it failed the check.
One other fascinating check is the one which corrects for digicam parallax. A machine takes pictures of a selected sample with every rear digicam after which calibrates accordingly. Then there are chambers to check the varied radios, like WiFi, Bluetooth, Extremely-Wideband, and NFC (particularly, Samsung Pay).
Given what number of elements there are, some are certain to fail inspection. Gadgets that fail a check are ejected from the meeting line and positioned on a rack for a human employee to examine. That is seemingly uncommon, nonetheless, as Samsung informed us throughout the tour that the failure fee is simply 0.7%.
The low failure fee could be attributed to the standard of elements, after all, but in addition to how optimized and automatic the method has develop 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 guide labor to pack the assembled telephones into packing containers and apply labels to them.
Nonetheless, Samsung is definitely operating a pilot line that absolutely automates your complete meeting course of, which incorporates packing. The road that assembled the Verizon Galaxy S23 Extremely was really a part of this pilot program, whereas the road for the Galaxy Z Fold 5 nonetheless had employees manually making use of the display screen protector and packing the machine into packing containers (with the assistance of varied instruments and machines, after all). Samsung informed us that it’s working to completely automate your complete meeting course of by the top of this 12 months; it’s already automated 9/12 steps within the course of however remains to be engaged on automating the consumption and verification of supplies from distributors.
It’s not over as soon as the telephones are assembled
The checks that Samsung’s robots run throughout the meeting line are hardly consultant of real-world use, however that’s not the purpose. These robots solely check that the {hardware} works to specification. Of their automation testing lab, Samsung places its telephones and smartwatches by way of a wide range of totally different situations to check varied options and mimic real-world use. These embrace:
- Accelerated getting older: Samsung runs a script that repeatedly loops by way of varied actions, like making a name, watching a video, and many others., as a way to extrapolate how the cellphone may behave and carry out after years of use.
- Exercise detection (swimming): Two smartwatches are positioned on the wrists of robotic arms that simulate a swimming movement.
- Bluetooth connections: A robotic continuously opens and closes the case of a pair of earbuds to quickly check Bluetooth connection/disconnection conduct.
- Fingerprint authentication: A robotic arm checks 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 several 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 residence of their lab full with mini curtains and lightweight bulbs subsequent to a full-size Samsung fridge and washer as a way to check varied 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.
- Strolling: A robotic holds a cellphone whereas barely vibrating and transferring forwards and backwards in a line to simulate a cellphone being held in your pocket.
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There have been a wide range of different automated checks being run on this lab that I can’t keep in mind now, however I undoubtedly keep in mind strolling by a bunch of various benches the place PCs have been operating varied 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 in a position to take any pictures or movies of it. Thankfully, the video that Samsung shared with us really exhibits off numerous what I noticed whereas touring the automation testing lab. Plus, this lab is definitely the place a number of the units that Samsung places up on its Distant Check Lab really come from, so protecting that tidbit behind my thoughts will certainly jog my reminiscence about this go to.
I hope I get the prospect to do one other manufacturing facility tour like this once more as a result of I undoubtedly realized lots throughout my go to to Samsung’s Good Metropolis. My focus is extra on the software program aspect of issues when you haven’t observed, which is why numerous what I noticed in Gumi was new and thrilling to me. There are nonetheless some particulars concerning the tour that I couldn’t discover a approach to slot into this text, like how Samsung checks its Extremely-Skinny Glass for foldables and the way Samsung carried out machine studying and distant work into their processes, however I’ve to finish this text someplace.
I’ll depart you with one thing amusing, although: Samsung’s Bixby-powered Galaxy Dwelling good 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 have been inconspicuously positioned behind a desk in one of many demo rooms, although I don’t keep in mind in the event that they have been really getting used. So I actually did get to see each Galaxy product Samsung ever made besides for the Word 7.
If you wish to take a look at the complete 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.
