Manufacturing automation for semiconductor customer

SYSTEMA helps semiconductor makers digitize and supports the whole value chain from production to testing. It combines system integration, consultation, and automation development.

One of the company’s large divisions develops software for managing semiconductor manufacturing. It’s called the Manufacturing Execution System (MES). Systema’s customer in this division is a Munich company that makes integrated circuits for 4G and 5G filters for a US processor manufacturer.

Systema needed high-end Java developers for a semiconductor client. They required experts with legacy code experience who could transition to newer technologies and speak German.

Project Aim:

– Upgrading the MES System for Modern Semi-Manufacturing Demands

– Automating Workflows for Increased Productivity

– Providing a stable base for automating production facilities and creating a “Smart Factory.”

VM engineers partnered with Systema for support throughout software development, from architecture to testing. The first major milestone was a stable process with a skilled internal and external team. We worked with the client in person and remotely. This hybrid approach succeeded because our experienced developers communicated well with the client, ensuring good communication and feedback.

Our cooperation was divided into several stages, from consulting to development and testing at the client’s site.

Consulting role

• Describing requirements – developing a concept for an information system for the management of automated production of integrated circuits

We hired a Business Analyst to assist the client. The analyst and the client’s team created a business concept and a solution design, outlining functional requirements. They documented their analysis using BPMN and UML notation and generated concept documentation in Enterprise Architect for developers to follow.

• Develop an agile management system

We added a Scrum Master to handle task execution. We divided the development period into monthly sprints and hold daily meetings. Tasks are run in Azure DevOps, allowing for scheduled execution and providing daily insights.

Development – Building software to manage and automate the production process

The work has several stages. It starts with discussing requirements with the client. Then, we provide software architecture, develop the source code, and test the product.

Our work is divided into three business divisions.

Project nr 1 – Dedicated SAP MES interfaces, customization of database structures, and consulting

• SAP PM-MES

Systema is extending the existing SAP PM-MES system to the manufacturing industry. Specialists from Systema and VM introduce standard solutions there. They use a customer-specific template and custom extensions to meet the customer’s needs and cover their use cases.

Challenge/Need 

 SAP is a standard that will never provide an integration interface for some manufacturers’ custom solutions. Thus, customers needed experts for tailored solutions. The experts had to build custom extensions on existing systems.

Solution

VM developers create custom solutions for one part of the SAP system used by clients. They work with SAP ERP, which has a plant maintenance module (SAP PM) connected to a custom MES. SAP PM manages equipment maintenance, including schedules and technician skills. Developers write SAP interfaces. They also customize databases and give technical advice based on the client’s needs.

• SAP ME/MII 

This is another project in our SAP department, where our developers work in this area together with different teams on different programs, using their knowledge and extensive experience.

Challenge

Different production processes need custom automations and tailored SAP functions. These include auto-assembling components, tracking labor, and responding to production errors. Each type of manufacturing needs its own equipment integration. It also needs to exchange data with other SAP or third-party systems. This often involves using standard IDOC/RFC or web services. A key goal is to create customized Production Operator Dashboards or reports for in-depth KPI analysis.

Solution

In this project we use JavaScript (SAP UI5) for the front end, Java SDK for the backend, and the third part is created by MAI, a blockchain software (we flip ready-made functions and customize them, combining them into algorithms).

The SAP MES (Manufacturing Execution Suite) project includes the following objects:

• SAP ME (Manufacturing Execution)

– Management AND control of all processes on the production floor based on ERP enterprise management specifications.

– ME records all information about the manufactured product during the production process, so it can be said that it is the basis of digital twin.

• SAP MII (Manufacturing Integration and Intelligence) 

– The technical foundation layer of MES.

– Integration with various systems

– Ease of implementation of new functionalities

• SAP MEINT (Manufacturing Execution ERP Integration)  

– Facilitates communication between SAP ERP AND SAP ME through the use e.g XSLT

– Communication methods:

SAP ERO->SAP ME: Idoc->XML

SAP ME->SAP ERP:XML->BAPI / RFC-Call

• SAP PCo (Plant Connectivity)  

– PCo enables you to communicate using a language that is understood by machines and their control systems (PLCs).

– Control of machines by providing and executing actions

– Requests for current data from the machine

Result 

Systema works with VM developers using their knowledge and extensive experience. Depending on the project requirements, the right specialists are matched.

Project nr 2 – Integrating machines into the automation landscape

Programmers develop an automation layer that controls machine processes and connects to the MES and external systems. This involves integrating machines into the automation landscape using two modules: EQC and EQS. The software automates machine steps, with back-end functionalities mapping events and commands to automation layer steps.

Challenge 

Machines are not standardized but customized for specific manufacturing processes. Therefore, to meet automation requirements, we had to fully understand many elements of the process beyond software development.

Solution

The VM team works with clients using the standard SDLC phases: analysis, design, implementation, and test. They test the final product in the factory using real equipment. Process engineers and software developers team up for this step.

The software automates machine tasks, so operators only need to set parameters and start the process. We’ve focused on back-end functionality.

Features 

The software works in a way that automates the steps a machine usually needs to do for processing. With that, the manual operation of the machine is no longer needed by an operator; all the operator has to do is start the process with the proper parameters. The functionalities are built exclusively in the back-end layer.

Project Features:  

• Industry standards
• Communication via factory bus, real-time data transfer

Result 

Machine integration speeds up the work of operators. Besides, we get several hundred measurement data for each wafer created in Space, MC300 or EADOS format.

Project nr 3 – Semiconductor and manufacturing management automation software

Our developers create products for clients in semiconductor and manufacturing management automation. The project involves automating production, connecting systems, and tracking data. It’s used to implement microservices architecture and features two web interfaces: one for configuring production and the other for supervising flow.

Challenge 

The project’s main challenge is processing and presenting a large amount of data. We’ve chosen a micro-service architecture with Tibco MOM to handle this efficiently.

The project is in its 4th year. It’s a distributed solution where VM developers build software stages. Our goal is to write standard-compliant software. We’re gathering requirements to define the interface.

Proceedings 
The project is now in its 4th year and is still continuing. Generally, it is a distributed solution; VM developers build specific software stages. The goal is to write software that fits the standards. To achieve this, we are gathering requirements to define the interface, such as how to move between specific applications.

Features 

Implementations included:

• A master data management system for setting up the system’s master data and therefore, it’s form of the fab’s “digital twin”,
• An execution engine for executing enhanced manufacturing automation scenarios during processing of goods
• Underlying framework for system integration and communication

Result

The software continues to be developed; we are developing the various parts of process automation.

As part of these complex projects we have been quick to get into the development process and help develop the Client’s systems in a shorter time. Currently, together with the Client’s team, we are working with world-class companies. ​​

We engaged more than 20 engineers with extensive experience and high competence during the project. We had a part in developing the concept of the entire IT solution and participated in its implementation and the implementation of the pilot solution. We are currently continuing development work and are part of the client’s team that can train new employees involved in the project.