Evolving Scale & Complexity in Smart Factories
How is IoT transforming the manufacturing landscape? Enterprises today face the imperative to evolve, particularly in precision-centric sectors like semiconductor production. During the pandemic, industrial manufacturers who proactively invested in technology not only weathered the downturn more effectively but also emerged stronger compared to those who reduced tech spending. As manufacturing operations become increasingly intricate, connectivity innovations are paramount for sustained success. Discover how ATEN solutions can pave the way.
Size of Smart Factory Market in USD by 2032
280
In 2022, the smart factory market surpassed $110 billion and is predicted to grow at 9% CAGR from 2023-2032, driven by demand for automation to ensure high-quality, reliable products. 1
Investing in Robotics & Automation by 2024
62
According to Deloitte, 62% of top manufacturers are investing in robotics and automation to accelerate production, cut costs, and address labor shortages. 3
Rise in Edge-to-Cloud IT/OT Convergence by 2024
60
By 2024, IDC forecasts that 60% of manufacturers will merge edge OT data with cloud analytics as standard site policy, considering this integrated data crucial for operations. 2
Digital Twin Asset Management Boost in 2023
50
According to IDC, in 2023, 20% of new manufacturing assets will be using preconfigured digital twins to speed up analytics outcomes by 50% for overall operations and processes. 4
Trends
Digital Twins Optimizing Production Processes
Real-time oversight of operations and assets is crucial, but it's also vital to simulate & observe production flows to quickly spot problems. Digital twinning employs data from sensors and IoT devices to create virtual replicas where cost-effective analysis and testing can be conducted. The findings can then be applied to enhance real-world systems and production processes. 1
5G Integration Unlocking New Possibilities
Besides facilitating digital twins and automation, 5G networks in smart factories also improve safety and efficiency. 5G enables more effective remote system monitoring and maintenance compared to older networks. It also paves the way for widespread use of technologies like VR and AR. As manufacturing evolves, it's crucial to strategize for 5G integration now. 2
Increasing Emphasis on ESG & Sustainability
Manufacturers are minimizing fossil fuel use and adopting renewables to fast-track their path to net-zero emissions. Traceability is a key focus, as companies aim to validate the origins of their product components. As consumer preferences tilt toward ethical and sustainable production, it's not just a moral imperative but also a business necessity. 3
Integrated Solutions Making Automation Accessible
Today’s deep tech offers full potential for automation across manufacturing applications, but initial costs for implementation are high. To mitigate these financial and human resource challenges, many providers are offering modular, affordable solutions that can integrate with existing facilities or act as standalone micro-factories, making automation easier to initiate. 4
Challenges
There are many challenges in developing access management systems for production lines:- Spatial Constraints & Outdated Equipment
Large semiconductor plants often span vast areas, making efficient on-site monitoring a challenging task; existing machinery, which may be expensive and difficult to replace, often lacks internet connectivity due to its legacy nature. - Sterility and Accessibility
High-tech production, especially wafer manufacturing, necessitates a pristine environment. This stringent cleanliness requirement limits the frequency of entry for equipment checks and maintenance. - MES Integration & Operational Complexity
While a flexible Manufacturing Execution System (MES) is crucial for maintaining quality and reducing costs, integrating excessive testing equipment can overwhelm the management system. This can lead to complicated recipe operations that are more susceptible to errors. - Restrictive Machine Software Protocols
Many original equipment manufacturers of high-end machines in production lines prohibit the installation of additional software, limiting customization and adaptability. - Control Framework & Emergency Protocols
Without localized priority settings, emergency control becomes less efficient. This underscores the importance of having a refined control system that can respond adeptly in critical situations. - Network Integrity & Cybersecurity Concerns
Implementing remote monitoring software introduces potential vulnerabilities to cyberattacks. Additionally, there are apprehensions that these implementations might compromise machine performance and subsequently, production capacity.
To address these multifaceted challenges inherent to high-tech production environments, ATEN has pioneered a range of RCM solutions. These are meticulously designed to offer a seamless, adaptable, and effective management interface for both production control systems and quality testing procedures.
Large semiconductor plants often span vast areas, making efficient on-site monitoring a challenging task; existing machinery, which may be expensive and difficult to replace, often lacks internet connectivity due to its legacy nature.
High-tech production, especially wafer manufacturing, necessitates a pristine environment. This stringent cleanliness requirement limits the frequency of entry for equipment checks and maintenance.
While a flexible Manufacturing Execution System (MES) is crucial for maintaining quality and reducing costs, integrating excessive testing equipment can overwhelm the management system. This can lead to complicated recipe operations that are more susceptible to errors.
Many original equipment manufacturers of high-end machines in production lines prohibit the installation of additional software, limiting customization and adaptability.
Without localized priority settings, emergency control becomes less efficient. This underscores the importance of having a refined control system that can respond adeptly in critical situations.
Implementing remote monitoring software introduces potential vulnerabilities to cyberattacks. Additionally, there are apprehensions that these implementations might compromise machine performance and subsequently, production capacity.
ATEN RCM Solutions
Understanding the intricacies of production lines is pivotal for maximizing efficiency and ensuring seamless operations. ATEN's RCM (Remote Control & Monitoring) solutions are not just tools but strategic assets. The benefits that our solutions bring to the production line environment include:- Safety & Efficiency:
A significant reduction in the frequency of personnel entries into sensitive zones like the production line or clean rooms, minimizing contamination risks and streamlining processes. - Holistic Monitoring:
The Panel Array Mode™ allows simultaneous monitoring of multiple machines, presenting an integrated view of the entire production floor, which is vital for swift decision-making. - Swift Emergency Handling:
Real-time emergency response and alarm monitoring ensure that any anomalies or malfunctions are detected and addressed instantly, minimizing downtimes and potential losses. - Smart Control Mechanisms:
Instant prioritization control ensures that resources are allocated optimally, and critical processes are given precedence. - Robust Security Protocols:
Our solutions come equipped with advanced authentication and authorization measures, ensuring that access is restricted to authorized personnel only, safeguarding sensitive data and operations.
In the fast-paced world of production lines, where every second and decision counts, ATEN's solutions stand as a beacon of reliability and efficiency.
A significant reduction in the frequency of personnel entries into sensitive zones like the production line or clean rooms, minimizing contamination risks and streamlining processes.
The Panel Array Mode™ allows simultaneous monitoring of multiple machines, presenting an integrated view of the entire production floor, which is vital for swift decision-making.
Real-time emergency response and alarm monitoring ensure that any anomalies or malfunctions are detected and addressed instantly, minimizing downtimes and potential losses.
Instant prioritization control ensures that resources are allocated optimally, and critical processes are given precedence.
Our solutions come equipped with advanced authentication and authorization measures, ensuring that access is restricted to authorized personnel only, safeguarding sensitive data and operations.
ATEN Solutions in Action
Remote Management + Robotics Process Automation (RPA) for OEM Semiconductor Manufacturing
An OEM semiconductor manufacturer requires accurate recording of operational settings and process data for quality control and review. However, the absence of an SECS/GEM interface in their current equipment leads to manual data transcription and inspections, which introduces the risk of human error. The company seeks an automated control system compatible with its MES that can perform automated checks, handle emergencies, manage test recipes, collect data, and maintain system logs to streamline production and enhance precision.
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Remote Monitoring & Control for Extensive Clean Room Operations
Navigating and managing large-scale clean room facilities can be highly challenging due to the sheer size and the inconvenience of entering and exiting these controlled environments. A leading manufacturer with a sprawling facility encompassing numerous clean rooms faced high maintenance costs and inefficiencies. They needed a sophisticated remote monitoring system that could oversee all operations comprehensively and reduce reaction times. Additionally, they sought a centralized control room capable of supporting simultaneous remote access by administrators for efficient problem-solving and server management.
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Tailored Remote Control & Monitoring for DRAM Manufacturing
As a prominent DRAM and flash memory chip manufacturer, maintaining peak production levels is critical amidst fluctuating market trends and competitive dynamics. The company sought a specialized remote control and monitoring (RCM) system to grant supervisors IP-based remote access to their costly production line machinery, ensuring uninterrupted operations across three shifts for 24/7 productivity. The desired RCM solution needed to integrate access hierarchy and web-based surveillance with sophisticated features, enabling them to meet batch production goals within strict deadlines while enhancing overall operational efficiency.
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Digital Transformation for PC Testing & Multi-View Monitoring in IPC Manufacturing
During their digital transformation initiative, a computer peripheral/IPC manufacturer sought an all-digital KVM over IP solution. This was to remotely oversee PCs across their expansive facility running diverse testing programs on multiple lines. Some lines focused on testing prototype designs and pre-production samples, while others were dedicated to system integration for OEM orders or build-/configure-to-order tasks. All these operations demanded strategic testing methods, PC diagnostic tools, troubleshooting aids, and data erasure utilities to guarantee robust computer hardware performance. Hence, a solution was needed that would seamlessly merge IT and OT, ensuring holistic server management.
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Optimizing Facility Management Operations for Equipment Cleaning & Coating Processes
A leading company specializing in cleaning and coating technologies for equipment parts in the semiconductor, display, and solar-photovoltaic sectors sought a comprehensive facility management solution. In such a PLC-driven production line environment, there is a seamless integration of numerous devices and software. Their primary aim is to monitor and automate production processes, optimizing the use and reuse of high-cost equipment. Effective management of this system demands continuous oversight of power meters, water-cooled chillers, dust collectors, and scrubbers. Additionally, it's crucial to monitor and control the PLC devices directly from the facility's control room, along with FFU control computers, to simplify operations and ensure timely responses.
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Assembly, Preparation, & IT Maintenance for Gaming PC Production Line, Europe
A well-known computer manufacturer specializing in pre-built gaming PCs was looking for an assembly line solution to optimize the machine preparation processes at its 300+ capacity plant.
Operators are required to configure and set up many computers during a process that involves assembly, BIOS flash and configuration, OS installation, component scanning for quality control, and testing. This involves with repetitive operations that are extremely time-consuming.
They were looking for a USB 3.0 high data transfer rate solution to configure multiple units at the same time instead of having to work on a one-at-a-time basis.
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Critical Monitoring for Assembly Plant & Clean Room, Panel Fabrication, South Korea
A global manufacturer of LCD panels had several manufacturing and module assembly plants that needed their critical monitoring and control systems to be upgraded to help maintain their competitive advantage. The production equipment is extremely expensive and requires 3 shifts of engineers for full-time 24/7 operation, with two engineers handling the control system for individual equipment, one in the fab clean room doing field operation and another in the control room doing remote monitoring.
The supervisor needed a solution to provide them with priority access, allowing them to take remote control of areas without needing extra staff in order to improve efficiency while reducing manpower costs.
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Multiple Workstation SCADA System Access for CNC Machining, Italy
An Italian SI, who develops and builds computerized numerical control (CNC) work centers with multiple operator consoles, wanted to build a SCADA PC system with access from 5 different operator consoles. All console workstations needed to be equipped with a touchscreen and a keyboard with touchpad and were allowed exclusive access to control machine tools on a one-at-a-time basis.
The SCADA PC, where the CCKM KVM over IP Matrix Manager software is installed, enables or restricts access from each workstation during a period of at least 10min. An automation PLC manages the ports. This all happens through machine-to-machine communication and frees up manpower for additional tasks while allowing for precise results on a repeatable basis.
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Conventional Production Line (R)
- Conventional industries
- Food manufacturing / Food processing
- Automotive manufacturing
- CNC production line
Feature in focus: KVM over IP Agility
In the realm of conventional industries, we can observe notable sectors such as food manufacturing and processing, automotive manufacturing, and CNC production lines. These industries are critical pillars of our modern economy and play a central role in shaping our everyday experiences.
A pivotal technological feature enhancing the efficiency and safety of these sectors is the KVM over IP Agility. This system provides remote access, ensuring convenient monitoring of processes and operations from virtually anywhere. In addition to offering heightened convenience, it prioritizes operator safety, ensuring that those overseeing production processes are not exposed to unnecessary risks. Furthermore, this feature offers BIOS-level access, guaranteeing in-depth system control. To bolster reliability and uptime, the system is equipped with dual power and LAN redundancy, ensuring operations continue smoothly even in the event of unexpected technical challenges.
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Semi-Smart Production Line (C)
- Technology Manufacturers
- PCB factory
- Equipment manufacturer
- IDM – Integrated Design Manufacturer
- Computer peripheral, IPC manufacturer
Features in focus: RCM & RCMMS
The RCM series, including models KE, KN, and CN, offers a comprehensive lineup tailored to cater to various needs, from budget considerations to installation environments that factor in cabling complexities and management efficiency. Central to this system is the RCMMS, a dedicated software for centralized management of RCM deployment. This software boasts an array of features.
- Panel Array Mode allows real-time monitoring of multiple machines or equipment, ensuring firsthand data and insights on all on-site equipment.
- Remote Access eliminates the need for physical presence at the production line when anomalies arise with equipment, allowing for remote operational control.
- The inclusion of RPA (robotic process automation) scripting automates routine workflows, scheduling tasks to execute on demand. This not only saves time but also removes the hassle of manual interventions on the production line.
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High-Tech Production Lines (M)
- High-tech manufacturers
- Semi-conductor manufacturers / wafer fabrication
- Wafer probe, wafer packaging
Features in focus: RCM API (software customization) & Industry 4.0
High-tech manufacturing, particularly in the semiconductor and wafer fabrication sectors, is evolving rapidly with firms like TSMC, UMC, and wafer probe and packaging specialists like ASE leading the way. A major point of interest for these manufacturers is the integration of advanced features like the RCM API, which facilitates system integration by allowing customization to mesh seamlessly with a manufacturer's existing production line management system. This API doesn't just stop at integration; it boasts features such as RPA, OCR, image comparison, and color recognition. Moreover, the push towards Industry 4.0 is evident with the implementation of unmanned factories, improved equipment runtime and uptime contributing to the enhancement of OEE (Overall Equipment Effectiveness), and the development of digital twin technology.
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