A transformative technology is reshaping the future of the manufacturing sector. The innovative approach integrates real-time physical data with advanced, real-time AI analysis to move smart factories beyond the conventions of automation and quality inspection methods. It allows manufacturers to utilize real-time physical data to glean new insights into their factory floors and predict the condition of machinery, throughput, and output to improve production efficiency, reduce costs and ensure product quality.

The key Secreta of seven step process to Advanced smart factory

MTS Reliability Technologies is the visionary behind this new era of ‘intelligent factories.’
Driven by a goal to change the outlook of industrial manufacturing operations, MTS leads the charge in the smart manufacturing revolution with its cutting-edge innovation– Real-Time Manufacture AI—along with Real-Time Physical Data and Real-Time Digital Twins.

Unlike traditional AI technologies that use historical data to identify patterns, MTS’s innovation acts on real-time data to analyze factory floors and predict the success or failure of the machinery and operations in real-time. With an auto compensation feature, the technology surpasses slow and imprecise automated optical inspection and big data techniques.

“Real-Time Technology is not just digital transformation but a real-time revolution, making smart factories more efficient, adaptive and competitive,” says Robert Tsai, managing director of MTS.

An industry veteran with extensive expertise in technology and engineering, Tsai is driven by a vision to redefine smart manufacturing.

Unleashing the Potential of Real-Time Technology

Real-time physical data is the key to smart manufacturing. By capturing and transmitting real-time information about production processes with instruments and sensors, the technology can provide valuable insights for process control and adjustments. The real-time sensor technology helps clients overcome the limitations of IIOT sensors, enabling accurate diagnostics, such as Real-Time Impedance, Real-Time Contact Force, Real-Time Contact Resistance, and Real-Time Pogo Pin Condition. The collected data includes parameters such as temperature, pressure, speed, thermal stress, and other physical variables that impact product quality and performance.

Effectively analyzing this physical data and monitoring machines using Real-Time AI to make intelligent decisions forms the other side of the equation. Real-Time AI includes Real-Time learning-based, physics-informed, domain-guided, computing-capable, data analysis, digital twin, auto setup precision and control technologies

Unlike traditional machine learning AI, Real-Time AI requires integration with physical models. Connecting to data sources like physical sensors and data twins, it captures data from deep machine layers. Analyzing this data and detecting potential issues, it immediately triggers AI high-speed computing and compensation or automatically adjusts equipment to avoid the production of defective products, making the process more flexible, efficient, and precise.

MTS’s Real-Time Manufacture AI paves the way for accurate smart AI supply chains, automatic and precise smart auto dispatch, and smart auto recipe management. With this, the company aims for operational precision of 99.9 percent.

When the machine is running, the team can reveal the real-time process capability index and quality. This can save up to 65 percent of manufacturing costs for clients.

For example, a silicon and SiC wafer production factory can use real-time physical data to ensure materials are within the correct crystal rod length and wafer warpage. When the information is processed through real-time industrial AI, the system can promptly provide feedback and adjust mechanisms and crystal parameters to prevent low yields.

The Secret To Creating Perfect Smart Factories Is Our Sevenstep Process That Leads To Enhanced Outcomes

Delivering Tangible Value from Smart Manufacturing

MTS draws on decades of experience building smart manufacturing solutions to assist clients worldwide in implementing cuttingedge Real-Time Technology. The powerful combination of realtime physical data, real-time digital twins and Real-Time AI has significantly increased output and improved yield for numerous manufacturers. This leads to exceptional results in many use cases, such as PCB manufacturing, SiC crystal growth furnaces, wafer grinding, wafer foundries, assembly and testing, power generation, paper, and petrochemical industries. The results include achieving zero warpage, a 100 percent yield, and reduced parts per million defects, paper breaks, faults, and chipping, along with a minimum of 50 percent increased output.

The success story of One of a leading provider of semiconductor manufacturing services in assembly and test–is a testament to MTS’s robust capabilities. Leveraging the technology for their Bumping Process at its bumping factory in Asia. MTS Manufacture AI-enabled Equipment, processes improved manufacturing yields and accuracy, to Improve and result in a hike in output by 60 Plus percent and an 85 percent alarm reduction. This bumping factory also inducted into the World Economic Forum’s Global Lighthouse Network, a community of manufacturing sites and value chains adopting Industry 4.0 cutting-edge technologies.

On another occasion, MTS’s real-time technology helped a client operating wire bonding, boost their speed from 2,800 to 9,600 units per hour with Auto Threading Technology and Real Time AI . IC Final Test OEE from 62% to 98% continuously for last 24 months

Making Factories of the Future a Reality

“In recent years, the term ‘smart manufacturing’ has been widely misused. Without making processes, equipment, and workflows intelligent, relying solely on digital analysis and deep learning to accelerate quality defect inspection does not provide any value,” says Tsai. “The secret to creating perfect smart factories is our seven-step process that leads to enhanced outcomes.”

The team begins by identifying the drivers and barriers–the root of smart manufacturing success. It pilots a machine model to prove its technology can change industrial manufacturing. After the successful pilot, the technology is applied to machines in the facility to reduce downtime and ensure high-quality production.

Following this is knowledge engineering, where MTS leverages its large database of domain knowledge to roll out complete solutions for all the devices in the factory.

In the next phase, various technologies are integrated to provide clients with value-added insights into manufacturing. The team factors in efficient, accurate, and controlled decision-making. Smart automation is then introduced to boost efficiency and throughput.

This process culminates in a smart manufacturing reality. MTS’s smart manufacturing is not just automation but a continuous journey where boundaries can be raised to deliver unparalleled efficiency.

Feature-Rich Manufacturing

MTS-driven smart factories incorporate many advanced features.

With Real-Time Recipe Auto Download, they can automatically access production recipes that best suit current production conditions based on realtime physical data feedback, and ensure products are always in optimal condition. MTS’s one-of-a-kind Real-Time Auto Setup allows production equipment to automatically adjust settings according to real-time physical data parameters, reducing the time required for production changes. With Real-Time Auto Dispatch, smart factories can automatically schedule production tasks based on demand and equipment status.

In some processes and equipment, automation only involves transporting finished or semi-finished products according to a fixed schedule. However, certain processes require precise positioning of molds, drilling and assembly of intricate components, and even tasks such as automatically fastening screws, and adjusting the positioning and stacking of objects while in motion. This often results in numerous workers navigating smart factories. In response, MTS has developed the Precision Micro-Level Auto Setup Technology, linking real-time data. Instead of relying on maps and using low-precision technologies like Bluetooth and 5G with indoor accuracy ranging from 20mm to many centimeters, it has introduced microlevel (um) rapid precision positioning based on spatial technology to address human errors.

Real-Time AI can also ensure industrial safety and contribute to net zero technology, optimizing energy savings and carbon emission reductions in real-time. The company offers its Smart Manufacture cyber-physical system solution to control components like sensors and actuators in an AI-driven manner.

By incorporating various data-driven, smart manufacturing technology solutions, MTS continues to improve global industrial manufacturing standards. Powering the company’s success is a worldwide team of nearly 2,000 domain specialists prioritizing customer- and value-centric approaches. The sheer dedication of its skilled team enables clients to reach newer heights in their smart manufacturing journey.

With the quest for excellence ingrained in its DNA, MTS stands at the threshold of a new, smarter manufacturing industry.