Visualizing the Future: How Indium Developed an Analytics Product for Predictive Maintenance & Data Visualization in the Semiconductor Industry
Client Overview
The client is one of the world's leading enablers of advanced semiconductor manufacturing, with its technology playing a crucial role in nearly every innovative chip produced today. Headquartered in California, the company provides value-added services to semiconductor manufacturers, specializing in the development and supply of wafer fabrication equipment and services.
With manufacturing centers across the Americas, Europe, and Asia, the client supports semiconductor production worldwide. Their chip-making process involves a complex sequence of individual steps, where each process module fabricates multiple wafers under precisely controlled conditions of temperature, pressure, and other critical parameters. Through its innovative solutions, the client empowers semiconductor manufacturers to push the boundaries of technology and innovation.
Building a Smarter Future: Data-Driven Goals for Semiconductor Excellence
The client sought a data-driven solution to enhance operational efficiency, ensure quality control, and drive predictive insights across the wafer fabrication process.
The key business requirements included:
Optimizing Wafer Production Efficiency
Utilizing data-driven insights to measure and enhance the efficiency of wafer fabrication processes. Also implement a system to record and store process
chamber conditions in real-time using sensor data, enabling continuous tracking of wafer fabrication.
Real-Time Production Line Monitoring
Ensuring continuous oversight of the wafer production line to detect and address inefficiencies.
Identifying Anomalies in Process Modules
Detecting outlier process modules to prevent deviations and maintain production consistency.
Predicting Defects Before They Happen
Leveraging advanced analytics to
forecast defects in process modules and reduce yield loss.
Proactive Maintenance for Uninterrupted Operations
Implementing predictive maintenance strategies to minimize downtime and enhance equipment longevity
Transforming Semiconductor Manufacturing with Advanced Data Analytics
Data into Actionable Insights:
A data science solution, integrated with a powerful visualization layer, was implemented to aggregate vast data volumes from process chambers and present them through an intuitive, actionable interface for key business users.
Scalable Data Management for Continuous Insights
The constant influx of process data demanded a robust database capable of handling both raw and processed (aggregated) data. A Hadoop-based solution was introduced to ensure efficient data storage and management.
Unlocking Actionable Insights from Processed Data
The processed data enabled key functionalities, including: Identifying outlier or anomalous process modules in regular production. Flagging defects in the manufacturing process for immediate action.Providing wafer-level insights, ensuring the highest possible resolution.Monitoring adherence to production guidelines to maintain quality and efficiency.
Visual Intelligence
Bringing Data to Life: Data insights were visualized using advanced visualization tools, making analysis intuitive and user-friendly. Charts delivered quick response times, allowing users to analyze large datasets without delays.
Advanced Data Exploration Features
Enabled interactive capabilities such as zoom-in, brush & deselect, simulations, pop-ups, and drill-downs for in-depth analysis.
Seamless End-to-End Analytics
From selecting specific Customers, Labs, and Process Modules to model building, the entire analytics process was streamlined into a single, actionable view.
Transformative Impact: Driving Efficiency, Cutting Costs, and Elevating Performance
3X Savings, Triple the Uptime:
Achieved enormous reduction in repair and maintenance costs, significantly minimizing downtime and enhancing the operational efficiency of process modules.
20% More Efficiency, Same Time—More Wafers
Boosted process module efficiency, enabling higher wafer production without increasing operational time.
A Game-Changer in Semiconductor Solutions
Developed a highly sought-after product that has become an essential offering for our clients, adding value to their customers and driving business success
About Indium
Indium is an Al-driven digital engineering company that helps enterprises build, scale, and innovate with cutting-edge technology. We specialize in custom solutions, ensuring every engagement is tailored to business needs with a relentless customer-first approach. Our expertise spans Generative Al, Product Engineering, Intelligent Automation, Data & Al, Quality Engineering, and Gaming, delivering high-impact solutions that drive real business impact.
With 5,000+ associates globally, we partner with Fortune 500, Global 2000, and leading technology firms across Financial Services, Healthcare, Manufacturing, Retail, and Technology-driving impact in North America, India, the UK, Singapore, Australia, and Japan to keep businesses ahead in an Al-first world.
