Client Profile
Client: A leading semiconductor manufacturing company in Japan.
Industry: Semiconductor Manufacturing.
Challenges
The client, a prominent player in the semiconductor industry, faced challenges in integrating their ACCRETECH TSK AD3000T dicing saw with their existing factory automation systems. The lack of a robust SECS/GEM interface led to inefficiencies, including:
Manual data collection, resulting in human errors and delays.
Limited visibility into real-time equipment performance.
Increased downtime due to delayed diagnostics and maintenance alerts.
Difficulty in achieving full automation, impacting productivity and competitiveness.
The need for seamless communication between equipment and the factory’s MES (Manufacturing Execution System) was critical to maintaining operational efficiency and achieving Industry 4.0 standards.
Testing & Validation
Comprehensive testing and validation were conducted to ensure seamless operation:
Connectivity Tests: Verified the stability and reliability of the SECS/GEM interface.
Functional Tests: Ensured accurate data transmission for all key operations, such as start/stop commands, process parameters, and alarm handling.
Stress Testing: Simulated high workloads to confirm the system’s robustness under peak operations.
Operator Training: Client teams were trained to maximize the benefits of the newly integrated system.
Solution
Einnosys provided a cutting-edge solution with its proprietary EIGEMBox, a compact, plug-and-play hardware device designed to enable SECS/GEM compliance. Key steps in the solution included:
Assessment:
A detailed analysis of the client’s requirements and equipment was conducted. The ACCRETECH TSK AD3000T was identified as a non-SECS/GEM-compliant tool, requiring a retrofit to enable seamless communication with the MES.
Customization:
The EIGEMBox was configured to integrate with the specific parameters and protocols of the AD3000T. Custom scripts were developed to enable the real-time exchange of data, including alarms, events, and operational parameters.
Deployment:
The EIGEMBox was installed and connected to the dicing saw. The process involved minimal disruption to ongoing operations, as the plug-and-play nature of the EIGEMBox ensured quick deployment.
Integration:
The EIGEMBox was integrated with the client’s MES, enabling two-way communication. Real-time data could now be monitored, analyzed, and used for decision-making.
Results
The integration of SECS/GEM on the ACCRETECH TSK AD3000T using the EIGEMBox delivered transformative results:
Increased Efficiency: Eliminated manual data collection, reducing errors and saving time.
Enhanced Visibility: Real-time monitoring provided actionable insights, enabling proactive maintenance and faster response to issues.
Improved Uptime: Downtime due to equipment failure or maintenance delays decreased significantly.
Full Automation: Achieved seamless integration with the MES, aligning operations with Industry 4.0 standards.
Cost Savings: Optimized operations led to a significant reduction in operational costs.