Enabling Digital Transformation
The amount of data generated in a modern wafer fab is very large. In one minute, 75,000 wafer moves can be recorded, and 360,000 recipe step events can be executed.
Today, most enterprise business decisions such as product costing, customer orders allocation and confirmation, can only be made using much more aggregated and less volatile data. Many semiconductor companies are transforming their overall processes and operations, and manufacturing is one of the most critical and value generating processes in a semiconductor company. Being able to tightly integrate manufacturing with the rest of the enterprise is a critical element of a successful digital transformation program. The goal is to use actual and near real time manufacturing data to support the key supply chain and enterprise use cases.
- Real-time Product Costing: Accurate and up-to-date cost information based on actual equipment usage and actual consumption of parts and consumables to better assess profitability
- Supply Chain Visibility: Enhanced control and management of work-in-progress (WIP) leading to lower working capital and improved order fill rate.
- Order Status and Yield Monitoring: Real-time updates on order status and yield leading to better order promising, fulfillment rate and customer satisfaction
- Quality and Reliability Management: Rapid identification and isolation of at-risk materials leading to improved product quality.
DOWNLOAD the Sapience Manufacturing Hub datasheet
The Sapience Manufacturing Hub solves the problem of getting actionable shop floor data to the top floor for a semiconductor company. Because the most complex wafers take 3-4 months to process through a fab with the number of process steps in the thousands, even dealing with a single wafer lot of data has proved to be an enormous challenge. Consequently, cost data associated with materials, labor and rework are allocated equally across all the products in the fab over many months. The result is that detailed data about how much a particular wafer costs or the profit margins of a product are buried in the averages.
The Hub is used to gather clean data from the factory floor and aggregate it where it makes sense. Milestone processes are used to report aggregated data by product, order, lot and other relevant factors so that costs can be accurately accounted for at the enterprise level. When the costs for energy, materials and testing go up while yields fall, knowing the details is important. The Sapience Manufacturing Hub is the first cloud-native platform that can scale using common and well-known data center tools and provide this data in a way that is useful to the corporate suite of applications.
