Extending the Life of Critical Semiconductor Manufacturing Equipment
A leading multinational semiconductor manufacturer approached FAST Technologies to modernise a critical wafer processing system that had reached end-of-life and was no longer supported by the original equipment manufacturer (OEM). With obsolete components becoming increasingly difficult to source, the customer needed a reliable, long-term refurbishment solution that would protect production, improve reliability and extend the life of the equipment without impacting existing manufacturing processes.
Challenge
Modernising Legacy Semiconductor Equipment Without Compromising Production
The customer’s existing equipment formed a critical part of its semiconductor manufacturing process, making replacement both costly and disruptive. Numerous electrical and control components had become obsolete, with no direct replacements available, increasing the risk of unplanned downtime and maintenance challenges.
FAST Technologies was tasked with delivering a complete refurbishment while maintaining:
- Existing process capability and stability
- Original machine footprint
- Current production throughput
- Compatibility with existing SECS/GEM communication protocols
- Support for multiple wafer sizes
- Compliance with the latest international machinery safety standards across installations in Europe and North America.
Solution
A Complete Control System Retrofit for Long-Term Reliability
FAST Technologies delivered a comprehensive refurbishment programme, replacing the legacy control architecture with a modern PLC-based system designed to significantly improve reliability and long-term supportability.
The project included:
Modern PLC Control System
The obsolete control platform was completely replaced with an industry-standard PLC solution, providing greater reliability, particularly during power interruptions and system restart cycles.
Electrical System Redesign
The machine’s electrical wiring was re-engineered to simplify maintenance, reduce system complexity and comply with current industrial electrical standards.
Robotic Handling Upgrade
FAST replaced the original wafer handling robot and pre-aligner with a new ISEL robotic handling system, improving positioning accuracy, reliability and long-term availability of spare parts.
Enhanced Operator & Maintenance Access
Machine access was redesigned to improve usability for operators while providing maintenance engineers with safer and more efficient access to key components, reducing servicing time and improving overall equipment maintainability.
Factory Integration
A bespoke GEM/SECS-II communications interface was developed to replicate the original factory communication protocols while introducing enhanced functionality, ensuring seamless integration with existing semiconductor manufacturing systems.
Project Outcomes
The refurbishment successfully extended the operational life of the customer’s critical semiconductor equipment while maintaining existing production capability and factory integration.
By modernising the control platform and replacing obsolete hardware with fully supported components, FAST Technologies delivered a solution that significantly improved system reliability, simplified maintenance and ensured the equipment remained compliant with current safety standards.
Results
- Complete replacement of obsolete hardware
- Modern PLC-based control architecture
- Improved operator usability
- Enhanced maintenance accessibility
- Full GEM/SECS-II compatibility
- Original production footprint maintained
- Multiple wafer size compatibility
- TÜV Certified safety compliance
- 5,000+ Hours Mean Time Between Failures (MTBF)
- Long-term support using industry-standard components
Looking to extend the life of your manufacturing equipment?
FAST Technologies specialises in the refurbishment and modernisation of legacy manufacturing systems, helping customers improve reliability, minimise downtime and maximise the return on existing capital equipment investments.
Contact our engineering team today to discuss your refurbishment requirements.