Delta's Big Data Analytics and Cross-factory Management Enhances Process Control for Semiconductor Manufacturing

The development of technology has brought us many electronic devices that are convenient and important to our daily lives. Devices we use from day to day may include a bedside alarm clock, a coffee maker, smart devices, as well as household items such as a water dispenser, refrigerator, HVAC, home theater, access control and intercom systems, vehicle remote controls and more. All of these electronic devices require a core control based on integrated circuits (ICs).

Silicon wafers used in the making of ICs are sliced from monocrystalline silicon ingots, which are made out of purified silicon oxide. Wafers are diced into many pieces called “dies”. Dies must undergo electrical tests and verifications before being packaged for protection against dust, moisture ingress and static electricity, and for heat dissipation. There are diverse packaging forms and various kinds of tests involved during the process. The managing of big data is a major driver in the increase of IC production.

Delta is proficient and experienced in industrial integration and recently introduced a semiconductor manufacturer in northern Taiwan to a statistical process control (SPC) system for better control of processes. The manufacturer owned multiple factories for wafer and die testing and IC packaging. After discussions with the manufacturer and understanding its requirements, Delta set the machine-to-machine communication specifications and instructed the manufacturer to install and operate the SPC system. With the integration of the SPC system and a manufacturing execution system (MES), users can monitor all the big data collected from testing and packaging factories in real time by simply operating the user-friendly interface. All manufacturing processes are under control and problems or anomalies can be immediately resolved.

This case adopts Delta's Statistical Process Control System DIASPC, which integrates with the customer's MES system to collect and upload the big data for IC manufacturing to the Cloud via standardized communication protocols. The DIASPC systemizes the IC production process, presents the analyzed data in various reports, and significantly reduces the time for manual data acquisition and analysis to increase yield.

The Delta's DIASPC system fulfills real-time monitoring and benefits the semiconductor manufacturer with the following features and advantages:

• Heterogeneous system integration for machine-to-machine communication
Delta connects together the customer's existing testing and packaging machines at different locations, and standardizes the communication protocols. Systematic management is well implemented without any extra cost or time for an additional set of hardware equipment. Delta broadens the value and extends the performance of the existing machines for the customer.

• Rapid big data upload
The huge amount of data generated during the processes of IC packaging and die testing is rapidly uploaded to the Cloud via standardized communication after the MES system has been integrated with the DIASPC system. This helps the customer monitor the production process in real time.

• Big data analysis for yield increases
The DIASPC system computes and calculates all the data collected and analyzes it well. With the big data analysis, problems can be easily identified during IC packaging and testing. The DIASPAC system can send out notifications when there is any anomalous event and help the customer dig out the root cause and reduce losses. It can also export analytical reports to substitute for manual data recording and calculating, contributing to better quality control and management.

• A web-based platform for cross-factory management
The data of multiple packaging and testing factories is retrievable on a web-based platform while these factories can be managed individually. The user-friendly operating interfaces turn each user into a fast learner and facilitate process monitoring in real time. With diversified reports exported from the DIASPC system, the customer can quickly aggregate cross-factory information and improve the subsequent production.

To prepare today's efficient management for tomorrow's better quality and competitive capabilities, Delta's DIASPC system handles the big data of production with ease and exports a variety of analytical reports. It provides a boost in yield increases, production process improvement, and multi-region and cross-factory management.