The Information is out with a detailed look today at the myriad difficulties Apple has faced trying to automate iPhone assembly and the building of other products.
The report claims that, beginning in 2012, Apple assembled a team of robotics and automation specialists at a secret lab in Sunnyvale, California to search for ways to reduce the number of workers on its production lines. However, the team is said to have quickly encountered challenges designing some of these automated systems.
Building a robot that can fasten screws is among the hardest challenges in the industry. A robot must pick up the screw at a specific angle and align it with a hole using multiple industrial cameras. Apple uses screws so tiny that robots had no way to measure the force used to drill them in. By contrast, human workers can feel the resistance from their hand and can tell when something is off.
As for putting glue onto display panels, Apple’s specifications are so tight that glue must often be placed within a millimeter of its desired spot inside a product. One former team member said well-trained Chinese workers were more adept at applying glue than their robot counterparts.
In early trials, the conveyor systems moved erratically, slowing down the movement of parts. A robot that installed the keyboard using 88 small screws kept malfunctioning, requiring humans to come in afterward and rework most of the process. Containers used for moving parts kept piling up on conveyors, creating traffic jams.
MacDailyNews Take: A famous scene just flashed in our minds (humans being overwhelmed, not robots, ironically):