Pure Storage’s assembly process operates from three key sites: two in Texas and one in Pardubice, Czechia. These locations focus on meeting regional demand, and we had the chance to see the assembly in Pardubice firsthand.
Pure shares space at a Foxconn facility, which is Czechia’s second-largest exporter, employing around 4,500 people. Their partnership goes back a decade, utilizing a facility that once housed a Tesla factory. This site is dedicated to assembling FlashArray and FlashBlade systems, producing 30 arrays and four blades each shift.
The Czech operation accounts for a third of Pure’s global assembly capacity. They can fulfill customer orders within two weeks. This site also manufactures upgrade components for customers on the Evergreen subscription model and replacement units. Typically, the facility runs one shift, but when necessary, it can ramp up to three shifts to support production needs.
Components arrive as sub-assemblies and parts from facilities in Vietnam, Mexico, and the US, all shipped by air. Notably, China is absent from the supply chain, as demand for diversification has grown due to geopolitical concerns. “We’re working to have zero from China,” says supply chain manager Jiri Černy.
Their production schedule is tight, meaning parts reach assembly just in time. An on-site warehouse holds stock and supplies components twice per shift, maintaining a stock of two days’ worth of parts.
The assembly process follows lean manufacturing principles, ensuring efficient workflows and minimizing errors. “It’s okay to make mistakes, but it’s foolish to repeat them,” Černy explains.
While the shopfloor staff may not have formal skills, their experience is invaluable. Most are women, and Černy believes they bring a sensitivity that is crucial. Many employees have been there for years and are well-acquainted with every assembly station.
These seasoned workers often collaborate with engineers, providing feedback that helps refine processes. Production remains heavily monitored; barcode tracking follows components through their lifecycle. Staff use instruction manuals displayed on monitors, which help adapt to ongoing changes in equipment configurations.
Cameras monitor the assembly process, not for strict oversight, but to document any issues that might arise. “We can track who built what and when. If something goes wrong, we can prove it didn’t happen here,” Černy reassures.
After assembly, each array undergoes strict testing for base and customer-specific configurations. Maintaining a consistent temperature of 24°C mimics datacenter conditions, while 35°C burn-in chambers stress-test hardware beyond normal operating temperatures.
This rigorous testing applies to all FlashBlade arrays and the first 1,000 units of any new configuration. Once inspected and packed, the arrays are ready for shipping.
But testing doesn’t stop here. At Pure’s R&D centers, systems built for customer setups can be tested for years, ensuring quality and performance. Plus, components are consistently refreshed for customers on the Evergreen subscription model, embodying the lean principles running throughout Pure’s operations.