Customer
Read-Rite Corporation. Fremont, California.
Background
Tight pH control of plating solution required, no remote monitoring/control system in place; data retrieved by technicians going into the fab and then manually updating an Excel spreadsheet
Solution
PC interface to each plating system
Upgrade Details:
- Automatic data collection of pH into Sybase SQL Server
- Provided client data extraction tool for quick analysis
- Created and installed remote control center to monitor many stations scattered throughout the fab
- Provided real-time scrolling trend charts to display current trend for each station
- Provided control switches to remotely control addback valves and flow rates to each reservoir
- With new tools in place, assisted customer with optimizing addback/replenishment algorithm based on product/layer type
- Remote lockout of the plating station from the control center
Customer
Sumitomo Sitix Silicon, Inc (SUMCO USA). Albuquerque, New Mexico.
Background
Customer possessed an Automated Wet Cleaning System which was in need of a process reconfiguration and Control System Upgrade.
Solution
Working closely with the customer to define the systems specification requirements, Superior Automation replaced the complete existing control system and integrated the SA 3000 Control System for the new process configuration.
Results
Customer achieved production goals and saved approximately 60% over purchasing a new system. In the last 2 years the system has maintained a high level of reliability and utilization.
| System Before the Upgrade |
System After the Upgrade |
| DOS Based | Windows NT Based |
| Scattered, non-intuitive screen layout | Intuitive Graphic User Interface |
| Scattered non-intuitive I/O layout | Logical and centralized I/O layout |
| Inflexible Recipe Sequencer | User friendly Recipe Editor |
| Non-flexible System Architecture | Flexible and open-architecture |
| Disjointed peripherals | Centralized control and monitoring of all peripherals |
| Limited system feedback No Data Management Tools | Supervisory Control and Data Acquisition package |
Additional Enhancements included:
- Programmable bath spiking
- Automated bath changes
- Closed loop Ozone Control
- Automated Safe Shut-down sequencing
- Advanced Error Recovery
- GEM/SECS Interface
- Remote Monitoring
- Optimized throughput through real-time multi-tasking scheduler
Upgrade Details:
- Replaced complete electrical system, including all power distribution and field wiring
- Replaced entire process and robot control systems with Superior Automation standard software tooling, consisting of:
o Netserver LH Pro w/RAID 5 for the GUI PC
o Wonderware FactorySuite in MS Windows NT 4.0 for the GUI front-end
o PLC Controllers, 1 ea. for process and 1 ea. for robot control
o Robot servo drive system, including custom modifications for increased reliability and logic level electrical isolation from I/O level, and power level signals or faults. - Added advanced error logging, handling, and recovery (operational safe shut-down, restart sequences)
- Added ozone concentration control for precise ozonation
- Added batch/equipment-centric data logging to MS SQL Server
- Added local and remote network connectivity, access
- Added lock/unlock capability due to SPC rule violation
- Added automatic chemical bath changes and bulk chemical dispense (BCD) interface
- Added Bar Code Reader interface
- Added WIP/Lot tracking interface to existing MES system
- Smoothed robot motion profiles
- Increased robot repeatability, reliability
- Implemented SA Multiple Batch Scheduler (SA 3000 Software Module), which handles tank contention and batch priority and will not over-etch batches in critical tanks.
- SA 3000 Software is also a Full Material Process and Material Transfer Model Simulation Tool
- Simulates time related issues such as Cycle Time and Throughput
- Allows prediction of real tool responses and operational scenarios
- Achieves tool optimization through strategic evaluation of process alternatives and dynamic resource allocations
Customer
KOMAG Corporation (Western Digital), Milpitas, California.
Background
Automation services needed to upgrade/modify existing CTC control software for an overhead gantry automatic palletizing system
Solution
Extensive System Modifications
Upgrade Details:
- Changed calibration sequence, cut calibration time from 5 minutes to 1 min
- Modified safety curtain interlock to allow immediate restart of system once safety area is clear (originally had to recalibrate every time)
- Changed gantry motion so that gantry always returned to center pickup position immediately after dropping off box onto the pallet, improving throughput (originally gantry would stop after dropoff and only return to center once it detects a new box at the center pickup position)
- Added box crush sensor input, interlocked to servo drive
- Added new box configuration and box locations into the data table
- Tied conveyor full sensor input to interlock the box-folding machine
- Modified operator interface display screen: Made it more user friendly and new capability to easily start, stop, recall, or park gantry system