Predictive Maintenance
Panasonic Connect needed a faster, less wasteful way for semiconductor manufacturers to optimize plasma dicing recipes and schedule equipment maintenance as chip packaging complexity increased and trial-and-error engineering cycles grew longer.
Reported impact
Panasonic Connect proved that AI-driven shop-floor analytics could shorten semiconductor process development, reduce maintenance costs for manufacturing customers, cut waste, and establish the foundation for more autonomous factory operations.
Panasonic Connect worked with IBM Research and IBM Consulting to turn shop-floor semiconductor equipment data into AI-guided process and maintenance decisions. The joint team used IBM Garage methodology to co-design two smart-factory applications for Panasonic's process automation business: one for plasma dicer recipe generation and one for plasma cleaner maintenance optimization. Deep learning algorithms built by IBM Research modeled variables such as vacuum pressure, power, electron energy, ion energies, and gases so engineers could simulate optimal recipes in seconds instead of iterating manually. A visual interface designed by IBM Consulting exposed those recommendations to engineers, while machine-mounted sensor data fed a second application that correlated operating efficiency with component condition to alert technicians to likely causes of underperformance and the best corrective action.
Process parameters and machine-status data from Panasonic semiconductor equipment feed IBM-developed analytics models; the outputs are surfaced through visual interfaces and maintenance alerts so engineers can refine plasma recipes and technicians can intervene before performance degrades.
The IBM Research team developed deep learning algorithms that — through huge numbers of calculations — enabled engineers to rapidly derive the optimal mix of variable points.
Using data from machine-mounted sensors, the application correlates changes in machine operating efficiency with the conditions of various machine parts.
engineers have an intuitive, visual interface [designed by IBM Consulting] that can simulate the process accurately and in just seconds.
reduce maintenance costs for manufacturing customers by 50%
the plasma cutting solution reduced the development cycle by as much as 30%
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