What’s new in SYSTEMA APS (Advanced Planning & Scheduling) v2024.4, SYSTEMA’s integrated solution for semiconductor shop floor scheduling and dispatching?

SYSTEMA APS v2024.4 builds on a robust platform proven through numerous successful deployments worldwide. This release introduces cutting-edge optimizations and refined user experiences to improve shop floor operations. With major new features aimed at streamlining workflows, enhancing real-time visibility, and expanding automation capabilities, SYSTEMA APS continues to set the standard for efficiency and operational excellence. Below are the key highlights.

Improved Scheduler Configuration UI

Our UI experts have revamped the web interface to allow for a much smoother and user-friendly scheduler configuration experience. The revised UI allows the configuration of an unlimited number of scheduler instances, tracking of operational metrics, configuration of the recompute plan for each schedule, and finetuning for all optimization settings. The UI serves as a cockpit for the modern line engineer and provides seamless integration with our operator and webFFC.

Improved Schedule Navigation and Search

With this release, navigating complex production schedules becomes simpler than ever. The new schedule views (including tool and pod schedules) provide pivoting, search, and filtering options, allowing users to quickly identify and focus on key scheduling data. This enhancement improves user efficiency and accelerates decision-making, ensuring that production managers can adapt to dynamic manufacturing needs in real-time.

Key benefits include:

  • Enhanced Search Capabilities: Filter schedules by critical parameters like lot ID, tool type, or task status.
  • Pivot Views: Allows for flexible data organization, presenting insights from different angles, including tool-specific or task-based views.
  • Integrated Filtering: Drill down to specific tasks and identify bottlenecks quickly using advanced filtering.

Next Task Dashboard: Real-Time Visibility

The “Next Task Dashboard” offers operators real-time updates on the status of each tool on the shop floor, from processing times to upcoming tasks. This dashboard displays equipment status in an intuitive, color-coded format, providing quick, actionable insights for decision-makers. Each tile on the dashboard represents a specific piece of equipment and reflects the current task status, remaining process time (RPT), and next task details.

Key benefits include:

  • Real-Time Updates: Continuous monitoring ensures operators and engineers have the latest information at their fingertips, minimizing tool downtime and optimizing production flow.
  • Visual Tool Status: The dashboard leverages a SEMI-E10 compatible color model to indicate tool conditions:
    • Green: Active, processing a lot.
    • Yellow: Standby, awaiting the next task.
    • Red: Tool issues or maintenance required.
    • Blue: Engaged in non-production tasks, such as engineering.

This feature significantly enhances operational efficiency by providing clear insights into tool performance and upcoming tasks, facilitating better planning and utilization of resources.

Built-in Feedback Model

For the first time, SYSTEMA APS includes a built-in feedback system in the operator web UI. This feature empowers users to directly provide feedback on the current schedule view. Users can capture snapshots of their screens, annotate the views with comments, and submit them directly to the system’s integrated ticketing service. These tickets are then monitored by line-control engineers, fostering a feedback loop between users and system administrators.

Key features include:

  • Screenshot Capture: Automatically attach the current schedule view when submitting feedback.
  • Seamless Ticketing: Feedback goes directly into the monitoring system for fast and efficient response from support teams.
  • Improved Communication: Enhanced user-to-support interaction leads to quicker resolution of issues and system optimization.

Line Control Automation Through the REST API

SYSTEMA APS continues to expand its automation capabilities. The SYSTEMA APS REST API has been upgraded to further enhance shop-floor equipment management, scheduling configuration, and real-time compliance monitoring. The API now provides flexible and robust endpoints for integrating factory operations with external systems, allowing full automation of processes from scheduling to user authentication.

Key benefits include:

  • Automation of Equipment Management: Configure tools, schedule tasks, and monitor compliance through a unified API.
  • Real-Time Tool Status Monitoring: Leverage API endpoints to track tool states and update schedules dynamically.
  • Integration with Factory Systems: Seamlessly integrate factory management operations with SYSTEMA APS, enhancing visibility across the production line.

New WIP Dispatch Optimization Methods

To address customer feedback, SYSTEMA APS v2024.4 introduces two powerful new dispatch rules focused on tool qualification:

  • Qualification Expiration Slack: Prioritizes lots nearing the expiration of their tool qualification, preventing tools from losing their qualifications and reducing the need for costly requalification processes.
  • Qualification Time: Ensures that jobs with shorter qualification times are processed first, maximizing tool throughput and minimizing downtime.

These enhancements ensure better management of tool qualifications, reducing overall non-productive time and maintaining tool readiness for high-priority jobs.

Digital Twin Enhancements

Significant improvements have been made to the digital twin model, enabling more precise and flexible modeling of production processes. Key additions include:

  • Sequence-Dependent Setup Times: Models setup times more accurately that depend on the sequence of tasks, leading to better scheduling and forecast accuracy.
  • Rework Routes: New schema definitions support arbitrary rework routes, improving flexibility in handling defective lots and reducing rework time.

These enhancements allow for better simulation of real-world production environments, providing more actionable insights for operators and engineers alike.

Enhanced Security with Role-Based Access

SYSTEMA APS v2024.4 introduces robust security measures with role-based access control (RBAC). This highly requested feature allows administrators to define access levels based on user roles, ensuring that sensitive configurations (such as scheduler settings) are protected. The system now supports multiple security modes, including lightweight Directory Access Protocol (LDAP) and Active Directory, providing flexibility for different organizational needs.

Improved Usability of the Web Interface

SYSTEMA APS v2024.4 enhances the overall user experience with several UI improvements aimed at making the web interface more intuitive and efficient:

  • Better Readability: Improved readability and overview of dispatching rules for easier understanding and decision-making.
  • Polished Visuals: Cosmetic refinements provide a more polished and user-friendly interface.
  • Enhanced Reporting: Improved report generation with advanced color scaling for clearer data visualization.
  • Real-Time Diagnostics: Enhanced tracking and visualization of schedule compliance with real-time diagnostics, ensuring users can monitor compliance efficiently.

Summary

SYSTEMA APS v2024.4 is a significant leap forward in improving real-time visibility, operational efficiency, and user feedback mechanisms. By focusing on key challenges in the semiconductor manufacturing space, this release continues to help users optimize WIP flow, reduce variability, and enhance predictability across the production line. With better tools for schedule navigation, security, and automation, SYSTEMA APS ensures that operators and engineers have everything they need to run a smooth, efficient, and secure production process.

Are you ready to take your production efficiency to the next level in 2024? Discover how SYSTEMA APS can transform your operations with a personalized demonstration and consultation. Our experts will guide you through the latest features and help identify opportunities for process optimization tailored to your specific production environment. To learn more about SYSTEMA APS, please contact us.