Client Overview
A leading semiconductor manufacturer faced production inefficiencies with their legacy SCREEN scrubber AS-2000, a critical tool for wafer cleaning. The equipment lacked SECS/GEM connectivity, forcing operators to manually log process data—leading to delays, errors, and compliance risks in their Industry 4.0-ready fab.
Challenge
Operational Bottlenecks Included:
No Real-Time Monitoring: Manual data recording caused delays in defect detection.
Non-Standard Protocol: The scrubber used a proprietary interface, incompatible with the fab’s SEMI E84/E87-based MES.
Compliance Risks: Inability to automate data logging for FDA/ISO audits.
Downtime Costs: 15+ minutes per shift wasted on manual checks.
Feature Highlights:
Zero Code Changes: No modifications to the scrubber’s OEM software.
FDC Integration: Enabled fault detection for particle count outliers.
Recipe Sync: Automated E87 recipe downloads from MES.
Solution
The client deployed EIGEMBox, a plug-and-play SECS/GEM communication gateway, to retrofit the scrubber with:
SEMI E30/GEM compliance
E84/E87 recipe management
Real-time equipment tracking
Key Implementation Steps:
Protocol Analysis: EIGEMBox engineers reverse-engineered the scrubber’s proprietary interface.
Hardware Integration: Installed a non-intrusive edge module to bridge communication.
GEM Scripting: Configured event reports (e.g., process start/end, alarms) per SEMI standards.
MES Testing: Validated data flow with the client’s Applied Materials MES.
| Component | Technology Used |
|---|---|
| Gateway | EIGEMBox (Linux-based) |
| Protocol | SECS-II, HSMS |
| MES Interface | SEMI E30/GEM, E84/E87 |
| Data Analytics | SQL Database + Grafana |
| Metric | Before | After |
|---|---|---|
| Data Accuracy | 78% (Manual) | 99.9% (Auto) |
| Downtime | 3 hrs/month | <30 min/month |
| Audit Prep | 8+ hours | Instant Reports |
ROI Achieved in 4 Months
Client Feedback
“EIGEMBox transformed our AS-2000 from a data black hole into a smart, compliant tool. We’ve eliminated manual logging errors and accelerated our smart fab roadmap.”
— Process Engineering Manager
Upgrade your legacy tools with SECS/GEM compliance—no OEM support needed. Contact us for a free feasibility assessment on your equipment.
