Intelligent manufacturing has become an inevitable trend in the innovation and development of the manufacturing industry. For the pan - semiconductor industry, building a black light factory is the ultimate goal of intelligent manufacturing upgrade. LOFA (Light Off Factory Assistant Black Light Factory Assistant) is opening a new page in the history of black light factory intelligent manufacturing through a vertical integration solution.
With the development of artificial intelligence and big data technologies, intelligent manufacturing has become an inevitable trend in the innovation and upgrading of the manufacturing industry and is also an important direction for accelerating the development of new quality productivity and promoting the digital transformation and upgrading of the manufacturing industry.
As one of the cornerstones of modern industry, the automation upgrade of the pan - semiconductor industry not only affects its own competitiveness but also has a profound impact on the overall development of intelligent manufacturing. For the pan - semiconductor industry, building a black light factory is the ultimate goal of intelligent manufacturing upgrade.
On March 18th, 2024, iyiou Think Tank jointly with Glorysoft officially released the "Research and Insight White Paper on the Development of Black Light Factories in the Pan - Semiconductor Industry", focusing on the upgrade, best practices, and future trends of black light factories in the pan - semiconductor industry. The report deeply understood the bottlenecks, pain points, difficulties, and weaknesses in the construction process of black light factories in industries such as semiconductor IC, semiconductor photovoltaic, and semiconductor display, explored the upgrade paths of black Light factories, and provided best practice references for the construction of black Light factories in the pan - semiconductor industry.
LOFA Initiates the Construction of Pan - Semiconductor Black Light Factories
In the Industry 4.0 era, the construction of a black light factory is not simply the stacking application of new technologies or new systems but a comprehensive project involving production standardization, networking, digitization, and other information systems, and considering factors such as planning and scheduling, production processes, material distribution, lean production, and safety and environmental protection. To achieve this goal, it is necessary to open up the information flow and data flow from enterprise management to equipment terminals. After the third industrial revolution, numerical control systems gradually became popular, and the factory side basically achieved single - point automation, but the separation of IT and OT and data islands are still pain points faced by most pan - semiconductor factories, urgently requiring the empowerment of a vertical integration solution.
As a well - known intelligent production solution software service provider in China, Glorysoft first proposed the concept of LOFA (Light Off Factory Assistant Black Light Factory Assistant) in the industry and first released the LOFA solution.
LOFA helps pan - semiconductor enterprises achieve vertical integration and improve the digital and intelligent level of the factory by running through remote control management, process automation, automatic defect classification, knowledge management, and business intelligence, and opening up the closed loop of data collection and analysis.
Figure: LOFA Helps Enterprises Achieve Vertical Integration
LOFA, as the unified entrance of the central control and combat service room of a fully automated factory, builds a smart central control AI brain of the factory by integrating factory management demand display, control, knowledge variet management, skill components, process automatic operation, AI recognition and analysis.
Figure: LOFA Black Light Factory Assistant Solution
Facing the Pain Points of Pan - Semiconductor Black Light Factory Upgrade, LOFA Provides the Best Practice Solution
Semiconductor IC and semiconductor display are core industries in the pan - semiconductor industry and face different pain points in the process of building a black Light factory.
The semiconductor IC industry chain as a whole belongs to a heavy - asset and talent - intensive industry. From the front - track semiconductor production and manufacturing to the back - track packaging and testing and assembly links, currently, there is a general need for cost reduction and efficiency improvement brought about by high - cost investment, the challenge of yield improvement brought about by the evolution of manufacturing process technologies, and industry talent bottlenecks.
Figure: Pain Points in the Construction of Semiconductor IC Black Light Factory
The automation level of the front - track link is relatively high, basically achieving full - process machine tool automation, but there are still pain points such as the improvement of personnel performance ability, the improvement of process link connection efficiency, and the automatic correction of equipment.
For the front - track factory, the assessment before the project and the processing of defects generated in the wafer process, the identification and classification work are all completed by humans, and the training period for personnel is long, and it is inconvenient to enter and exit the clean room, and the misjudgment rate is high relying on personnel experience, and the accuracy cannot be guaranteed. Therefore, an automatic defect detection scheme is needed to save human efficiency and improve accuracy. For this, LOFA uses a combination of PCC/RCM + Bots + AI product solutions to help 12" front - track factories achieve human savings, quality inspection experience accumulation, yield improvement, and process automation execution rate improvement.
Figure: Best Practice for the Automation Upgrade of 12" Front - track Factory
The automation level of the back - track packaging and testing link is generally lower than that of the front - track. Currently, packaging and testing enterprises are actively laying out the construction of black Light factories, but they still face pain points such as cost reduction and efficiency improvement, low automation level, and low detection accuracy during the process.
For packaging and testing factories, the focus of the construction of black Light factories is on achieving automatic loading and unloading of machine tools, selecting formulas, eliminating alarms, and other automatic operation processes, customizing the functions of old machine tools, and replacing humans to save costs. LOFA uses a combination of PCC/RCM + Bots product solutions to help enterprises save humans, precisely monitor, and upgrade machine tools.
Figure: Best Practice for the Automation Upgrade of Large Packaging and Testing Factories
The PCBA (Circuit Board Production Process Flow) link as a whole faces pain points such as intensified market competition, labor shortage, and quality improvement. Especially in the SMT industry, due to the large number of AOI equipment models, the misjudgment rate varies, the cost of equipment replacement is high, and the NG pictures need to be manually re - judged, and the misjudgment and omission probabilities of the judgment personnel are high, so an automatic detection scheme is urgently needed to empower. LOFA uses a combination of PCC/RCM + Bots + BI integrated solution to help SMT factories improve the judgment accuracy of pictures, optimize the human - machine ratio, and achieve efficient central control management.
Figure: Best Practice for the Automation Upgrade of Large SMT Factories
The semiconductor display industry is a typical capital - intensive and labor - intensive industry. In China, the LCD panel process is mature, accounting for about 70% of the global output, but in the OLED, MLED, and other new display fields, there are still challenges such as high investment costs and yield improvement.
Figure: Pain Points in the Construction of Semiconductor Display Black Light Factory
Panel manufacturing has high requirements for the production workshop. Currently, the frequent entry and exit of personnel are concentrated in the repair and detection links. LOFA uses a combination of PCC/RCM + Bots + AI solution to bridge the breakpoints in the panel process and improve the automation efficiency.
Figure: Best Practice for the Automation Upgrade of Large Panel Enterprises' Factories
Facing the Standards for the Construction of Black Light Factories, LOFA Provides the Best Product Form
From the practice of pan - semiconductor enterprises, most enterprises usually pay the most attention to the past project experience of service providers and the low invasiveness of their systems when selecting service providers during the construction of black Light factories.
Figure: Selection Standards for Service Providers in the Construction of Pan - Semiconductor Black Light Factories
As the first integrated solution in the pan - semiconductor industry, LOFA can provide higher system connectivity for enterprises on the basis of rich industry experience and service experience, reducing the trial - and - error costs of enterprises.
Figure: Advantages of LOFA Solution
At the same time, based on the combination of PCC/RCM、Bots、AI and other products, LOFA can provide values such as centralized control operation and automatic detection for pan - semiconductor factories, and also has competitive advantages in terms of professionalism, data security, system reliability, and low invasiveness.
Figure: Highlights of LOFA Solution
Opening a New Chapter in Black Light Factory Intelligent Manufacturing and Initiating a New Era for the Pan - Semiconductor Industry
From the overall situation of manufacturing digitization, although the pan - semiconductor industry is in the forefront, there are still problems such as lack of overall strategic planning, lack of comprehensive technical consideration, and talent shortage in the construction of black Light factories. To address these challenges, enterprises should clarify their strategic positioning, comprehensively plan their technical routes, and attach importance to talent cultivation.
The pan - semiconductor industry is technology - intensive, and its progress is not achieved overnight. The continuous enrichment of personnel experience is two cornerstones of industry development. To achieve the effective precipitation and efficient reuse of knowledge, a powerful knowledge management system needs to be built to promote experience exchange and technology sharing, thereby promoting the continuous and healthy development of the industry.
Figure: Systematic Precipitation of Knowledge through Knowledge Engineering to Overcome Talent Bottlenecks
The knowledge base, as an important part of the LOFA solution, is constantly strengthening the foundation of the industry. As an important carrier for storing and transmitting the "essence" of the industry, it enables the accumulation and inheritance of the achievements of industry civilization and wisdom.
LOFA has opened a new chapter in black Light factory intelligent manufacturing and has also initiated a new era for the pan - semiconductor industry. Let's look forward to the new story of LOFA in 2024.
