Pure Storage’s assembly operations hinge on a strategic three-site system, including two locations in Texas and a facility in Pardubice, Czechia. This European site plays a crucial role in meeting regional demand for the company’s flash arrays. A visit to the Pardubice assembly plant illustrates its extensive operations and the collaboration with Taiwanese contract manufacturer Foxconn, which employs 4,500 individuals in the region, marking it as Czechia’s second-largest exporter after Skoda.
Assembly Process and Infrastructure
The Pardubice facility, partially housed within a former Tesla factory from 1964, is dedicated to the production of Pure Storage’s FlashArray and FlashBlade systems, with the capability of producing 30 and four units per shift, respectively. This site accounts for one-third of the company’s global assembly capacity. Orders are fulfilled swiftly, typically within two weeks from receipt to delivery. In addition, the plant manufactures components for upgrades and replacement units as part of Pure’s Evergreen subscription service.
Components arrive as sub-assemblies, including controllers and power supplies, sourced from plants in Vietnam, Mexico, and the US, though Pure aims to eliminate reliance on Chinese suppliers due to geopolitical factors. According to Jiri Černy, the supply chain manager, the goal is to achieve a supply chain free from Chinese components in the near future.
Production Efficiency
Production at Pure is highly efficient, operating on just-in-time principles that ensure timely delivery of parts to assembly lines. A larger warehouse at the Foxconn site stores a significant inventory, ensuring that materials are available as needed. Lean manufacturing processes are in place, supported by methodologies like Six Sigma, which help minimize errors and improve production quality.
Assembly operations are overseen with strict adherence to quality control. Staff are not formally skilled but possess a deep understanding of their roles and are regarded as essential team members. A notable aspect of the workforce is the large proportion of women, whose sensitivity and attention to detail contribute positively to the production environment. Experienced operators often collaborate directly with engineers, providing valuable feedback on production processes.
Quality Control and Testing
Production processes are closely monitored, with the lifecycle of components and assemblies tracked via barcodes. Workstations utilize on-bench monitors to display instruction manuals, ensuring that staff remain updated with the latest configuration changes stemming from field feedback. CCTV cameras are installed not to surveil workers, but to maintain an evidence trail in the event of product issues.
After assembly, all products undergo stringent testing procedures. Standard configurations, referred to as “vanilla,” and personalized configurations, known as “chocolate,” are subjected to rigorous inspections. The facility maintains a controlled temperature of 24°C to simulate data center conditions, with additional burn-in testing conducted at 35°C for FlashBlade arrays and for the initial production of any new configurations.
Finally, completed arrays are meticulously inspected and packaged for shipment. Pure Storage’s commitment to testing and quality continues even after the initial sale, with ongoing evaluations of systems designed to emulate customer setups. Additionally, components are refreshed for clients enrolled in the Evergreen subscription service. This systematic approach aligns with Pure’s lean operational principles, ensuring efficiency and adaptability in their manufacturing processes.