Many semiconductor companies are involved in digital transformation of their overall processes and operations. Manufacturing is one of the most critical and value generating processes in a semiconductor company. Being able to integrate tightly manufacturing with the rest of the enterprise is a critical element of a successful digital transformation program.
Recognizing the value of real-time manufacturing data, SAP and PDF have partnered to develop the Sapience Manufacturing Hub. This innovative product integrates factory floor data with ERP and business planning solutions, offering a comprehensive approach to smart manufacturing.
The Sapience Manufacturing Hub leverages the strengths of Exensio, an advanced analytics platform, and Sapience, a versatile manufacturing connectivity solution. The hub connects various manufacturing data sources to the ERP system, addressing key customer needs such as real-time product costing, supply chain visibility, and order status monitoring.
Key Solutions and Capabilities: The Sapience Manufacturing Hub provides several essential solutions:
- Real-time Product Costing: Accurate and up-to-date costing information.
- Supply Chain Visibility: Enhanced control and management of work-in-progress (WIP).
- Order Status and Yield Monitoring: Real-time updates on order status and yield.
- Quality and Reliability Management: Rapid identification and isolation of at-risk materials.
Data Integration and Transformation. The hub connects to factory floor systems, MES systems, equipment, and supply chain data, transforming and summarizing this information into a format that the ERP system can understand and absorb. This integration bridges the gap between the shop floor and enterprise business, providing valuable insights into the manufacturing process and enhancing business planning and analytics.
Comprehensive Data Collection. The hub collects a wide range of data types from the shop floor, including wafer manufacturing data, PCM data, equipment data, MES information, and tool FDC data. This comprehensive data collection improves quality, delivery, and efficiency across the supply chain.
Orchestration and Data Management. The hub manages data orchestration, transformation, and storage, ensuring high availability and disaster recovery. It filters, aggregates, and transforms data into a usable format for the ERP system, maintaining data integrity and security.
Deployment and Integration. The Sapience Manufacturing Hub integrates seamlessly with factory control systems and enterprise applications, providing a unified interface for data management. It supports standard communication protocols and compliance, ensuring smooth data transmission and integration.
Value and Benefits. The Sapience Manufacturing Hub simplifies the integration between the shop floor and the top floor with a low-code/no-code solution. This approach reduces implementation costs and accelerates data integration.
The Sapience Manufacturing Hub supports multiple use cases of high importance to semiconductor manufacturing and other high-tech sectors. Here are some notable examples:
- Real-Time Product Costing:
- Use Case: A semiconductor manufacturer needs to accurately calculate the cost of each product in real-time.
- Benefit: The hub provides real-time integration of tool and FDC data and consumable consumption data from the MES the ERP system, enabling much more precise actual product costing allowing better financial planning.
- Supply Chain Visibility:
- Use Case: A company wants to monitor the status of work-in-progress (WIP) items across multiple manufacturing sites.
- Benefit: The hub offers enhanced visibility into the supply chain, allowing for better control and management of WIP, leading to improved efficiency and reduced delays.
- Order Status and Yield Monitoring:
- Use Case: A manufacturer needs to track the status and yield of orders in real-time to ensure timely delivery and quality control.
- Benefit: The hub provides real-time updates on order status and yield, helping manufacturers manage production schedules and maintain high-quality standards.
- Quality and Reliability Management:
- Use Case: A company faces quality issues with certain components and needs to quickly identify and isolate at-risk materials.
- Benefit: The hub enables rapid identification and isolation of defective materials, reducing the risk of quality issues and improving overall product reliability.
- Geographical Supply Chain Management:
- Use Case: A manufacturer operates multiple production sites globally and needs to manage supply chain disruptions due to geopolitical events or natural disasters.
- Benefit: The hub provides real-time visibility and management of the supply chain, allowing for quick adjustments and minimizing the impact of disruptions.
- Advanced Packaging and Assembly:
- Use Case: A company involved in advanced packaging needs to trace and manage multiple components from different suppliers.
- Benefit: The hub offers comprehensive traceability and data integration, improving the quality and efficiency of advanced packaging processes.
- Final Test and B2B Process Management:
- Use Case: A manufacturer needs to monitor the final testing of products and manage the transfer of components between sites.
- Benefit: The hub provides real-time monitoring and management of final test processes and B2B transactions, ensuring smooth operations and timely deliveries.
- Data Orchestration and Transformation:
- Use Case: A company needs to handle large volumes of data from various sources and transform it into a usable format for ERP systems.
- Benefit: The hub manages data orchestration, transformation, and storage, ensuring data integrity and security while providing valuable insights for business planning.
These use-cases demonstrate the versatility and value of the Sapience Manufacturing Hub in enhancing operational efficiency, improving product quality, and optimizing supply chain management.
Conclusion The Sapience Manufacturing Hub offers significant benefits, including quick deployment, accurate data transformation, and improved supply chain predictability. By linking shop floor data with business systems, it enhances operational efficiency, profitability, and customer satisfaction.
Click to find more information on the PDF Solutions Sapience Manufacturing Hub and our work with SAP .
SemiEngineering recently hosted a round-table on the value of bringing together manufacturing and financial data which SMH enables. You can read about it here.