Universal Scientific Industrial: A Deep Dive into D(MS)2 and Industry 4.0
Introduction
Universal Scientific Industrial (USI), a global leader in System-in-Package (SiP) and Electronic Manufacturing Services (EMS), has evolved significantly since its inception in 1976. This article delves into USI's core offerings, its commitment to innovation, and its advancements in smart manufacturing, providing a comprehensive overview of the company's operations and strategic direction.
USI's Global Footprint and D(MS)2 Services
USI boasts a substantial global presence, with 30 production and service locations spanning Asia, Europe, the Americas, and Africa. This extensive network enables USI to offer diversified electronic products and a comprehensive suite of D(MS)2 (Design, Manufacturing, Miniaturization, Industrial software and hardware Solutions, and material procurement, logistics and maintenance Services) product services. These services cater to a wide range of customer needs, from initial design and manufacturing to miniaturization, industrial solutions, and ongoing material procurement, logistics, and maintenance.
USI’s acquisition of Asteelflash and Hirschmann Car Communication has significantly expanded its manufacturing capabilities and global reach. With Asteelflash, USI added 17 manufacturing sites and approximately $1 billion in topline revenue. Today, USI has 27 manufacturing locations in 10 countries, employing over 24,000 people and generating more than $7 billion in revenue, securing its position as a major player in the EMS industry.
Celebrating Innovation and Sustainability
USI marked its 50th anniversary in 2026, celebrating a half-century of innovation and growth. The company's 50th-anniversary video, "Shine on Greatness," pays tribute to its decades of contributions to design, manufacturing, miniaturization, and sustainability. This milestone underscores USI's enduring commitment to pushing boundaries and delivering cutting-edge solutions.
Furthermore, USI has been recognized in the S&P Global Sustainability Yearbook for the 5th consecutive year, an honor earned by ranking in the Top 5% of the global ITC industry and scoring industry‑leading results across key ESG categories. This recognition highlights USI’s commitment to responsible growth, resilience, and long‑term impact, encompassing environmental excellence and human‑centric values.
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The Rise of Glass in Automotive HPC
As vehicles increasingly transform into mobile data centers, traditional substrates are encountering limitations. USI is pioneering the use of glass as a solution for High-Performance Computing (HPC) in automotive design. This innovation represents a design revolution for EVs and autonomous driving, offering enhanced performance and efficiency.
Smart Manufacturing and Industry 4.0
USI is deeply committed to Industry 4.0 principles and has implemented a detailed Smart manufacturing plan and roadmap known as the "Worldwide 5 Star I4.0 Smart Manufacturing Roadmap and Management System." This plan outlines a stage-by-stage approach to elevate the Smart manufacturing capabilities of USI's factories worldwide.
Data Automation
Data automation is at the core of USI's Industry 4.0 strategy. The company digitizes and connects all data to a central server, providing real-time insights from production equipment and processes. This includes SPC (statistical process control) data and RMS (recipe management system). Every production lot is scanned in and out at each process station using 2-D barcodes, ensuring complete traceability throughout the production line.
Automatic Material Handling System (AMHS)
USI has implemented an Automatic Material Handling System (AMHS) that fully automates the entire process of component delivery, from incoming materials to the warehouse to dispatching via AGVs (Automated Guided Vehicles) to SMT (Surface Mount Technology) pick-and-place machines in JIT (Just-In-Time) mode. This eliminates the need for a kitting room and associated labor, streamlining the material handling process.
Shop Floor Management System
Every machine in USI's factories is linked to a Shop Floor management system, which is connected to the company's ERP (Enterprise Resource Planning) system. This integration allows for real-time monitoring of material levels and ensures that machines are never running out of components.
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AI-Based Learning System
USI is leveraging AI-based learning systems to optimize inspection criteria and reduce both over-rejects and under-rejects. This technology enables machines to automatically adjust inspection parameters, fine-tuning the process to account for various variables.
Standardized Platforms and In-House Design
USI employs a common platform strategy to standardize data automation protocols and equipment, reducing development lead times and costs. The Zhangjian factory in Shanghai serves as the central hub for Smart manufacturing development.
While integrating standard, off-the-shelf, third-party production software, USI also focuses on in-house design and programming for automation equipment. The company uses SECS/GEM protocol for two-way data transfer, allowing the central server to control machines and receive real-time data. For older machines without SECS/GEM, USI has developed its own protocols using LORA IoT to monitor machine status.
AGVs and Lights-Out Testing
USI utilizes AGVs extensively to automate material transport within its factories. The company is working towards creating its first lights-out test floor factory, where AGVs will carry carts of parts to elevators and then to systems next to the machines that need them. This is supported by a Smart Storage system that manages component reels using robots.
Performance Measurement and Improvement
USI conducts studies to assess the impact of automated systems, focusing on accuracy and efficiency. The company uses a "five stars" rating system to measure the level of automation in its factories. This system considers the automation rate of the manufacturing process, the percentage of machines connected to the data system network, machine downtime reduction, and the reduction in direct and indirect labor headcount.
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SMT Production Lines
USI prides itself on having some of the best SMT production lines globally, known for their speed and accuracy. These lines are grouped by process to maximize machine efficiency. The company uses large-size PCBs with a high density of components, often ranging from 100 to 400 units per substrate.
Parameter Management System
USI has implemented an inline SPC system for component placement accuracy on its SMT lines. This system measures and collects data, feeding it to an SPC control module to detect process deviations. The company also automates outgoing cosmetic inspection processes to identify even the smallest defects.
Supply Chain Integration
USI is working towards integrating its ERP system with its customers' and suppliers' ERP systems to create a fully integrated supply chain. This would enable automatic inventory checks, yield loss calculations, and component-level demand forecasting, streamlining the entire supply chain process.
Challenges and Future Directions
Despite the advancements, USI faces the challenge of integrating older equipment into its Smart manufacturing ecosystem. The company is addressing this by developing its own protocols to connect older machines to the central server.
Looking ahead, USI is committed to continuing its investments in Smart manufacturing and upgrading its manufacturing capabilities to enhance its competitiveness. The company aims to achieve full integration of its supply chain and further optimize its production processes through AI-based learning systems.
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