Services and Solutions

Nexplant MESplus MC

Machine Control
Machine Connectivity solution to enable machine automation

Shop floor problems

Pain Point

We have too much equipment data and it's hard to collect and process them in real time.
I've been manually recording equipment data and an error is a common thing.
We need to respond appropriately to various requirements in accordance with an addition of new equipment.

We have too much equipment data and it's hard to collect and process them in real time.
I've been manually recording equipment data and an error is a common thing.
We need to respond appropriately to various requirements in accordance with an addition of new equipment.

Countermeasures

You require an automated solution for real-time collection and control of machine data.

Standard solution for real-time production machine data collection and bidirectional communication
Implementation of an optimized machine connectivity system: In response to additional arising requirements from existing machines, in line with the adoption of new machines
Machine interfaces/control/management systems to enable quick response to line/machine/system expansion

Solution

A machine control/machine connectivity solution that is designed to realize bilateral communication between production equipment and upper-level systems — such as MES and QMS — without protocol restraints

Conformity

In Compliance with SEMI’¹⁾s SECS/GEM²⁾ and OPC³⁾ Foundation’s OPC UA⁴⁾ 1) SEMI (Semiconductor Equipment and Materials International) 2) SECS/GEM stands for SECS(SEMI Equipment Communication Standards) and GEM(Generic Model for Communications and Control of Manufacturing Equipment), the standard published and maintained by SEMI 3) Open Platform Communications (OPC) is an interoperability standard for the secure exchange of industrial automation data. 4) OPC UA - The OPC Unified Architecture (OPC UA) is a machine-to-machine communication protocol used for industrial automation and developed by the OPC Foundation.
Flexibility

Equipment data collection over various protocols and provision of data transformations and conversion function
Convenience

Implementation of workflow logic and provision of interface simulator in a modelling format development environment
Reliability

Ensuring reliable system operation by real-time inspection of machine connectivity and system failure analytics

Conformity

In Compliance with SEMI’*s SECS/GEM* and OPC* Foundation’s OPC UA*
Flexibility

Equipment data collection over various protocols and provision of data transformations and conversion function
Convenience

Implementation of workflow logic and provision of interface simulator in a modelling format development environment
Reliability

Ensuring reliable system operation by real-time inspection of machine connectivity and system failure analytics

Nexplant MESplus MC

Experience what makes MC unique and how MC can help you collect machine data stably and support seamless connectivity between old and new machines.

Key Features

Feature 1.

Data Collection Made Easy
- Provides 6 types of key EAP information *6 types of key EAP information 1. Status information: Idle, process, down 2. Production-related information: Number of units produced, number of defects 3. Event: Event for each step 4. Alarm information: true, false 5. Recipe information: Name, parameter 6. Real-time process information: temperature, flux, velocity *EAP : Equipment Application Program
- Built-in function for data collection of various conditions
- Various (numeric) function data for data processing
- Consistent modeling functions in different communication protocol environments
Feature 2.

Rapid and flexible deployment through machine modeling
- GUI-format message definition tool providing a convenient development environment with least codes
- Minimized development man-hours by leveraging workflow designer for manufacturing process/line changes and additions
- Logging tools and communication simulators for real-time testing and analysis of results when configuring EAP
Feature 3.

Manageability and ease of operation
- Real-time machine monitoring and failover configuration to minimize the likelihood of system failures
- Integrated monitoring of factories and equipment operations across multiple sites
- Stable system operation with failure analytics capabilities through various reports and log analytics
Feature 4.

A wide range of machine-to-machine, machine-to-system communication protocols provided
- SEMI standards(SECS-I, HSMS), TCPIP, TELNET and various protocols
- OPC UA/DA Client are provided for PLC equipment communication
- Message Middleware (Highway101, TIBCO RV, MQ, etc.) Communication

Customer Benefits

Equipment utilization rate picking up

Quick detection of machine running status by real-time equipment monitoring and provision of reporting/alarm systems to increase equipment uptime
Reduced maintenance costs

Modeling-based solutions enabling quick response to process/equipment changes.

Increased efficiency of IT managers with an operating system that minimizes manual work.
Reliable equipment data

Securing reliable machine data by collecting large and real-time high-speed data without omission
Real-time machine monitoring

Sending the collected data to upper-level systems such as MES, QMS, and integrated control to enable data-based decision-making such as analytics/monitoring

Customer Success Stories

The customer, one of the world's largest manufacturers for its high-quality, high-efficiency solar cells and modules, was challenged with the rising difficulty in integrated control required to keep pace with their increasing number of overseas factories. They requested Miracom for an easy-to-use system to enable multiuser remote monitoring across their sites. Miracom deployed an automated, comprehensive control system based on high-tech BP practices. Miracom also developed a multi-fab (fabrication) remote monitoring and control system capable of processing large amounts of data at ultra-high speeds. The solution provider also developed a real-time equipment control system that standardized interfaces for each equipment model, enabling the customer's integrated control of domestic and overseas factories. The system implementation enabled remote response by the firm's experts at home in case of problems at overseas sites and reduced management costs by half.

The customer, an electronics manufacturer, advanced its existing MES by adding machine connectivity and manufacturing intelligence functions to secure production data-based competitiveness. With a system for analyzing raw material shipment information and machine data, Miracom implemented an integrated operation system linked to ERP and applied a real-time monitoring report function for visualization. As a result, the response time in case of abnormalities was reduced by 50% compared to the past and the machine utilization rate was up by 10%.

The customer, a semiconductor packaging and testing company, applied Miracom's Machine Control (MC) solution to the entire semiconductor post-processing process to implement equipment interfaces and automation based on standards set by the SEMI (Semiconductor Equipment and Materials International). The company also implemented interfaces with host systems such as bill of materials (BOM) and lot tracking and succeeded in improving productivity based on reliable equipment information.

The customer, which came in third to develop the world's industrial synthetic diamond, applied Miracom's MES and MC solutions as it promoted the expansion of MES to overseas factories. Through machine automation, the firm could minimize inefficiencies caused by manual work and improve production quality and efficiency by implementing a system that enables traceability between factories. In particular, by configuring an integrated dashboard for domestic and overseas factories, real-time machine operation status analytics was made possible, enabling more efficient management of manufacturing sites.