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Playstation's secret weapon: a nearly all-automated factory

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Re: Playstation's secret weapon: a nearly all-automated factory

#161

Earlier quoted context omitted.

I had invested in a semiconductor factory early last decade, and it had started making bitcoin miners, it had reminding me of Zion from the Matrix because it seemed like the first time that a machine could make another machine which could immediately start earning a negotiable asset and then transacting for resources. Very surreal to think about.

There was this little game I played on Linux years ago where you played an AI trying to reach singularity status while evading detection by humans. https://en.wikipedia.org/wiki/Endgame:_Singularity Early in the game, you'd hack machines to run mechanical-turk style jobs to earn money. Later you'd build a factory to manufacture more processors... ;)

That sounds like it has some Universal Paperclips vibes.

Re: Playstation's secret weapon: a nearly all-automated factory

#162
post #45

Lots of folks here are talking about the latency and throughput, but nobody is amazed at what the robots are doing. Plugging in cables and putting down tape is fiddly and hard. I'm super impressed that they elected to automate those things based on cost merit. Massive kudos to the manufacturing engineers who managed to pull that off.

Every discussion of highly-automated factories brings to mind this: https://www.youtube.com/watch?v=dSj6kvv7_Sg Early lights out production. The problem became obvious a little later, for NeXT, which was that these things only make sense at very high scale for products that change infrequently.

Years ago I worked for a company that had a PCB production line, and even for relatively low volumes (compared to consumer electronics) they used basically that exact process. The PCBs would be printed elsewhere and delivered in flat stacks, the boards would go through pick-and-place, solder bath, reflow, through-hole, wave solder, sometimes xray inspection, etc. Also had a tour of an Iomega plant when I was much younger with similar processes.

Not sure if NeXT was a pioneer in those techniques, but they seemed standard by the late 1990s and 2000s.

Re: Playstation's secret weapon: a nearly all-automated factory

#163
post #92

Earlier quoted context omitted.

Controls engineer here - no, that's pretty normal. I'm accustomed to automotive work, but I believe the electronics assembly lines are similar. The flexible materials handling stuff (connecting flat flex cables? Applying Kapton tape?) is indeed super impressive, but the timing is ordinary. A sizeable 6-axis robot like those used here has a minimum cycle time of a second or two for the simplest possible "move in, plac…

Thanks for your insight. Out of curiosity, why don't more of such production lines have dedicated machines that each do one small/simple action and then send it to the next one. It seems many seem to deploy general purpose robots that mimic human hand/arm features (that I would imagine have a higher latency cost in terms of controlling,positioning,etc). Is it so that you can manufacture multiple products with differe…

> Out of curiosity, why don't more of such production lines have dedicated machines that each do one small/simple action and then send it to the next one.

Specialising your tools or machines comes at a cost: inflexibility, specifically changeover time between different products. If your machine can only do exactly one thing, the changeover time is "physically replace the machine", which may mean a delay of months.

Changeover time is a massive, hard-to-see drag on everything in a factory. The ideal manufacturing machine station can instantly switch its use between any two consecutive products moving along the line. Physically impossible, but ideal. Fully-programmable robots are much closer to that ideal than single-purpose machines.

That said, the tradeoff depends on the product/process spectrum. Some products are produced in "job shops", meaning an extremely flexible, high-touch environment, turning out very short runs. Others are worker-paced or machine-paced (which is what the Playstation factory would count as), mostly this is used for consumer goods. These still retain some flexibility, as much as sensibly possible.

At the far end are "continuous process" plants. These are very specialised to the product. Bottling plants, chemical plants, oil refineries and so on, where flexibility is not a highly meaningful advantage and the product lends itself to being treated as an undifferentiated flow as opposed to discrete units of product.

I recommend Matching Supply with Demand by Cachon & Terweisch as a first book to read. Then follow with the more in-depth Factory Physics by Hopp & Spearman.

Re: Playstation's secret weapon: a nearly all-automated factory

#164
post #132

When will Sony start supporting Vulkan on PS?

I seriously doubt it. The PS4 has a custom graphics API which directly creates command buffers in the GPUs native format. There's not really much of a graphics driver at all other than what's necessary to isolate the game from the OS.

Re: Playstation's secret weapon: a nearly all-automated factory

#165

Earlier quoted context omitted.

The later Pros supposedly have revisions to make them less loud

They must, I've been playing TLOU2 on my ~1 year old PS4Pro and it's very quiet, almost silent. I've never heard it make much noise on any game, even when ambient temps creep into the mid 80's.

It depends how you have it placed, too. I played on a 2 year old Pro and it was extremely loud, but I have it stuffed in a media center cubby, so it's always suffering from low airflow.

Re: Playstation's secret weapon: a nearly all-automated factory

#166
post #35
post #15

Earlier quoted context omitted.

> Hows about selling a more open system that allows end-users to tinker and contribute themselves? We could even call these novel x86 devices "personal computers".

Yes! This is what I was driving at. Looping history back to the days of the C64, Amiga, Spectrum etc. where home tinkerers could make a massive contribution to the ecosystem. These were the gaming consoles of their day. Yes there were the NES and Atari 2600 but the popularity of something like the C64 is something that modern console vendors (especially at the PS4 price-point) should be falling over themselves for.

The PS3 ran Linux at the beginning. That went nowhere for Sony apart from a lawsuit when it got patched out and consoles getting racked for cheap compute at the beginning.

I don't remember the specifics apart from the GPU being inaccessible which just made it a PowerPC server. But i suspect that experience killed off the idea internally for quite a while.

Maybe it would be a last resort if the Playstation does lose out to game streaming (not that i think it will).

Re: Playstation's secret weapon: a nearly all-automated factory

#167
post #90

Earlier quoted context omitted.

There's no way they can build an entire one in just 30 seconds. It probably takes longer than that just to package them.

Well, the packaging is done by humans.

No, it isn't. The article specifically describes the robots packaging the final product.

Re: Playstation's secret weapon: a nearly all-automated factory

#168
post #45

Lots of folks here are talking about the latency and throughput, but nobody is amazed at what the robots are doing. Plugging in cables and putting down tape is fiddly and hard. I'm super impressed that they elected to automate those things based on cost merit. Massive kudos to the manufacturing engineers who managed to pull that off.

Every discussion of highly-automated factories brings to mind this: https://www.youtube.com/watch?v=dSj6kvv7_Sg Early lights out production. The problem became obvious a little later, for NeXT, which was that these things only make sense at very high scale for products that change infrequently.

Just wanna say I love this video. Thanks for posting this.

Re: Playstation's secret weapon: a nearly all-automated factory

#169

Earlier quoted context omitted.

Every discussion of highly-automated factories brings to mind this: https://www.youtube.com/watch?v=dSj6kvv7_Sg Early lights out production. The problem became obvious a little later, for NeXT, which was that these things only make sense at very high scale for products that change infrequently.

these boards werent consumer producs though. playstations are produced for years with no alterations.... millions of times. i.e. playstation 4 was sold ~100million times. thats most definitely at a scale where you can automate with margins.

Game console manufacturing definitely is low-mix compared to cars, but it's not like they're stamping out spoons: depending on how you count, there were something like 19 revisions to the PS3 motherboard, as Sony worked to reduce chip count and shrink PCB size: https://www.psdevwiki.com/ps3/Motherboard_Revisions

Re: Playstation's secret weapon: a nearly all-automated factory

#170
post #3

In case anyone misses the link in the article, they have a graphic-rich version: https://vdata.nikkei.com/en/newsgraphics/sony-playstation/ (The content is different, though both articles cover the same topic. A bit weird)

Thanks, the link on that page wouldn't do anything for me.
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