Automation as a System Upgrade: Improving Production Efficiency at Goldsun’s QV1 Facility

Manufacturing efficiency is often discussed in terms of speed or output. In practice, however, it is more closely related to how well a system can operate with consistency, control variability, and adapt to increasing requirements.

This perspective guided the recent automation upgrade of our rigid box assembly line for Samsung mobile packaging, completed in April 2025 at the Que Vo 1 (QV1) factory.

The original production model relied heavily on manual operations, particularly in stages such as cushion placement, assembly verification, and final packaging. While functional, this setup introduced variability and limited the overall efficiency of the line.

The upgraded system moves toward a **high level of automation—approximately 90%—**with manual intervention remaining primarily at the final carton packing stage. Automation has been introduced across multiple key processes, including:

• Cushion feeding and attachment to the box base
• Lid-and-base box assembly
• Orientation verification of internal components
• Surface cleaning (dust removal)
• Automatic polybag packing

In addition, we have integrated a camera-based inspection system, designed to detect errors such as incorrect assembly direction or mixed components. This system operates in real time, enabling immediate correction and reducing the likelihood of defects progressing through the line.

The transition from manual to automated processes has produced measurable changes. The number of operators required has been reduced from 19 to 7, while productivity per operator has increased from approximately 79 units per hour to 128 units per hour. Overall, this represents an increase to around 163% of the previous productivity level.

More importantly, the upgrade has improved process stability. Automated systems execute tasks with consistent parameters, reducing variation and improving repeatability. This contributes directly to more uniform product quality and fewer defects.

From a cost perspective, the reduction in labor and improvement in efficiency provide a stronger foundation for long-term optimization. At the same time, the system is better positioned to handle higher volumes without a proportional increase in resources.

This upgrade also reflects external requirements. For customers such as Samsung, automation is not only a performance improvement—it is part of the expected development path for suppliers. Annual roadmaps increasingly include automation targets, requiring suppliers to demonstrate continuous capability enhancement.

By implementing this system, we are aligning our operations with those expectations while also strengthening our internal manufacturing capability.

Looking forward, automation will continue to play a central role in how we develop our production systems. The focus is not only on increasing automation rates, but also on improving how different technologies—robotics, inspection systems, and data tracking—work together as an integrated system.