MES integration Archives

Success Story: SECS/GEM Integration on Disco DFG8560 Using EIGEMBox

Posted on July 31, 2025 by mike.brown

[vc_row][vc_column width=”1/2″][vc_column_text css=””]Client: Leading Semiconductor Fab, Philippines
Industry: Semiconductor Manufacturing
Product Used: EIGEMBox by eInnoSys
Equipment: Disco DFG8560 Back Grinder[/vc_column_text][/vc_column][vc_column width=”1/2″][vc_single_image image=”36675″ img_size=”full” alignment=”center” css=””][/vc_column][/vc_row][vc_row][vc_column][vc_column_text css=””]The client, a major semiconductor manufacturer in the Philippines, faced a critical automation bottleneck. Their Disco DFG8560 Back Grinder, a high-performance wafer thinning tool, lacked native SECS/GEM communication capabilities. This limitation hindered integration with the fab’s MES (Manufacturing Execution System) and AMHS (Automated Material Handling System), resulting in:

Manual data logging and recipe management
Increased risk of human error
Limited remote monitoring and control
Reduced overall equipment efficiency (OEE)

Upgrading the equipment or replacing it with newer models was not financially viable, with estimated costs exceeding $3 million.[/vc_column_text][vc_row_inner][vc_column_inner width=”1/2″][vc_column_text css=””]

Solution

The fab partnered with eInnoSys to deploy EIGEMBox. This patented plug-and-play solution adds SECS/GEM capability to legacy equipment without any hardware or software installation on the tool itself.

Using only the display output (HDMI) and optional keyboard/mouse ports, EIGEMBox captured the machine’s GUI and translated it into SECS/GEM-compatible signals. This enabled:

Full host communication
Remote start/stop and recipe download
Real-time data collection and fault detection
Seamless AMHS integration using E84/E87 protocols

Setup took less than an hour, with zero downtime or risk to the grinder’s operation.[/vc_column_text][/vc_column_inner][vc_column_inner width=”1/2″][vc_column_text css=””]

Testing & Validation

The integration was validated through a series of rigorous tests:

Recipe Management: Verified remote recipe download and execution.
Data Logging: Confirmed real-time parameter exchange and historical data capture.
Automation: Enabled remote start/stop and alarm monitoring.
AMHS Compatibility: Successfully integrated with the fab’s E84/E87-based material handling system.

All tests passed with high reliability, and no adverse effects were observed on the grinder’s performance.[/vc_column_text][/vc_column_inner][/vc_row_inner][/vc_column][/vc_row][vc_row][vc_column][vc_column_text css=””]

Results

100% SECS/GEM Compliance achieved on a previously non-compliant tool.
Zero Equipment Downtime during deployment.
Improved OEE through automation and reduced manual intervention.
Cost Savings: Over $3 million saved by avoiding equipment replacement.
Enhanced Yield: Prevented scrapping of ~194 wafers annually due to improved process control.

[/vc_column_text][/vc_column][/vc_row][vc_row][vc_column][vc_column_text css=””]Client Feedback

“EIGEMBox transformed our legacy Disco DFG8560 into a fully automated, SECS/GEM-compliant tool in under an hour. The integration was seamless, and the impact on our fab’s efficiency was immediate. We’re now rolling this out across other legacy tools.”

— Fab Automation Lead, Semiconductor Manufacturer, Philippines[/vc_column_text][/vc_column][/vc_row][vc_row][vc_column][vc_column_text css=””]Ready to modernize your legacy semiconductor tools without costly upgrades?

Discover how EIGEMBox can instantly enable SECS/GEM compliance and boost fab automation.
📞 Contact us today for a free consultation or demo.

🔗 Visit eInnoSys.com | ✉️ sales@einnosys.com[/vc_column_text][/vc_column][/vc_row]

Success Story: SECS/GEM Integration on ACCRETECH TSK AD3000T Using EIGEMBox

Posted on May 30, 2025 by mike.brown

[vc_row][vc_column width=”1/2″][vc_column_text css=””]Client Profile
Client: A leading semiconductor manufacturing company in Japan.
Industry: Semiconductor Manufacturing.[/vc_column_text][/vc_column][vc_column width=”1/2″][vc_single_image image=”35969″ img_size=”full” alignment=”center” css=””][/vc_column][/vc_row][vc_row][vc_column width=”1/2″][vc_column_text css=””]Challenges

The client, a prominent player in the semiconductor industry, faced challenges in integrating their ACCRETECH TSK AD3000T dicing saw with their existing factory automation systems. The lack of a robust SECS/GEM interface led to inefficiencies, including:

Manual data collection, resulting in human errors and delays.

Limited visibility into real-time equipment performance.

Increased downtime due to delayed diagnostics and maintenance alerts.

Difficulty in achieving full automation, impacting productivity and competitiveness.

The need for seamless communication between equipment and the factory’s MES (Manufacturing Execution System) was critical to maintaining operational efficiency and achieving Industry 4.0 standards.[/vc_column_text][vc_column_text css=””]Testing & Validation

Comprehensive testing and validation were conducted to ensure seamless operation:

Connectivity Tests: Verified the stability and reliability of the SECS/GEM interface.

Functional Tests: Ensured accurate data transmission for all key operations, such as start/stop commands, process parameters, and alarm handling.

Stress Testing: Simulated high workloads to confirm the system’s robustness under peak operations.

Operator Training: Client teams were trained to maximize the benefits of the newly integrated system.[/vc_column_text][/vc_column][vc_column width=”1/2″][vc_column_text css=””]Solution

Einnosys provided a cutting-edge solution with its proprietary EIGEMBox, a compact, plug-and-play hardware device designed to enable SECS/GEM compliance. Key steps in the solution included:

Assessment:
A detailed analysis of the client’s requirements and equipment was conducted. The ACCRETECH TSK AD3000T was identified as a non-SECS/GEM-compliant tool, requiring a retrofit to enable seamless communication with the MES.

Customization:
The EIGEMBox was configured to integrate with the specific parameters and protocols of the AD3000T. Custom scripts were developed to enable the real-time exchange of data, including alarms, events, and operational parameters.

Deployment:
The EIGEMBox was installed and connected to the dicing saw. The process involved minimal disruption to ongoing operations, as the plug-and-play nature of the EIGEMBox ensured quick deployment.

Integration:
The EIGEMBox was integrated with the client’s MES, enabling two-way communication. Real-time data could now be monitored, analyzed, and used for decision-making.[/vc_column_text][/vc_column][/vc_row][vc_row][vc_column][vc_column_text css=””]Results

The integration of SECS/GEM on the ACCRETECH TSK AD3000T using the EIGEMBox delivered transformative results:

Increased Efficiency: Eliminated manual data collection, reducing errors and saving time.

Enhanced Visibility: Real-time monitoring provided actionable insights, enabling proactive maintenance and faster response to issues.

Improved Uptime: Downtime due to equipment failure or maintenance delays decreased significantly.

Full Automation: Achieved seamless integration with the MES, aligning operations with Industry 4.0 standards.

Cost Savings: Optimized operations led to a significant reduction in operational costs.[/vc_column_text][/vc_column][/vc_row]