Author

Skills: MES Consultant | System Testing | System Modeling | User Training | Content Creating

Etching Cluster Tools

Vendors often integrate multiple etch chambers into one platform and each chamber can run different etch chemistries. Chambers may specialize in: oxide etch, nitride etch, metal etch, poly etch, high‑aspect‑ratio etch, etc. When one or more chambers go down, they can be removed from the Cluster to be repaired. This doesn’t mean a full production shutdown. Products that don’t depend on the capabilities of the affected chambers can still run.

Sputtering or Metal Deposition Equipment

Sputtering tools are one of the clearest and most common examples of true cluster equipment in semiconductor fabs. They typically include:

• A central transfer module (Load Lock) with a robot
• Multiple process chambers, each performing a different metal deposition
• Each chamber can be independently used and repaired without stopping production.

Although more common in Semiconductor Industry, this scenario can also exist in other industries

Plasma Surface Treatment Tool for Medical Device Industry

Used for instance for catheter bonding prep, stent surface activation, syringe barrel cleaning. These equipment have typically a central load/unload, a set of plasma chambers in parallel and each one of them can run different gas recipes. When one of the chambers is down and no alternative is available, some products that depend on that chamber may be forced to stop, while other products can continue to be manufactured

The use case shown in the demo below refers to the Metal Deposition process performed on a NEXX Sputter tool. Sputtering is a physical vapor deposition (PVD) technique widely used to deposit thin metal layers onto semiconductor wafers and it’s one specific technique of Metal Deposition process. It works by:

1. Creating plasma
2. Accelerating ions toward a metal target.
3. Condensing those atoms onto a wafer, forming a uniform, high‑purity film.

Sputtering is ideal for a wide range of metals used in semiconductors industries, such as:

• Aluminum (Al)
• Copper (Cu)
• Zinc (Zn)
• Silver (Ag)
• And other materials

For product “2EDN7524F”, the process requires an initial Aluminum deposition (qualified on CHB‑001 and CHB‑003) onto all the wafers, followed by a silver deposition step performed in CHB‑004

For product “KommSemi Generic Brand Gate Driver”, all the wafers require an initial silver deposition qualified on CHB‑004, followed by a Zinc deposition step performed in CHB‑005 and finally a Copper Deposition on CHB-002

For product “2EGN7524G”, all wafers require an initial Copper deposition, which is available on CHB‑002. This is followed by an Aluminum deposition that may be executed on either CHB‑001 or CHB‑003, and finally a Zinc deposition step performed on CHB‑005

⚙️MES SETUP

1st) The Sputtering Tool provides 3 different Main Services

2nd) Each one of the services is required by different products

3rd) The Main service “Sputtering Al_Ag” requires the sub-services “Aluminum Deposition” and “Silver Deposition” provide respectively by the Chambers “CHB-001 or CHB-003” and “CHB-004”.

The Main service “Sputtering Cu_Al_Zn” requires the sub-services “Copper Deposition” and “Aluminum Deposition” and “Zinc Deposition” provide respectively by the Chambers “CHB-002”, “CHB-001 or CHB-003” and “CHB-005”.

The Main service “Sputtering Ag_Zn_Cu” requires the sub-services “Silver Deposition” and “Zinc Deposition” and “Copper Deposition” provide respectively by the Chambers “CHB-004”, “CHB-005” and “CHB-002”.

DEMO

Note: Since the Aluminum Deposition Service can be executed by two different chambers, whenever this service is requested, the MES Running Mode functionality can be leveraged to dynamically select and trigger the appropriate process recipe based on the specific chamber allocated for execution

Final thoughts

Even if a chamber goes down, MES keeps production moving by tracking which chambers are available in real time and which products can run. This way, many products can still run without major disruption.

It’s a simple way to keep the line productive, even when equipment isn’t at full capacity.

Author

Hi! My name is José Romeu Bogas Gonçalves. 😉

I’ve been with Critical Manufacturing since 2018, starting out as an MES Consultant. In 2025 I stepped into the Advocate & Architecture team. My role sits at the intersection of technology, communication, and strategy. Making sure solutions are technically sound and that everyone understands how to use or build them.

You can check me on LinkedIn

Skills: MES Consultant | System Testing | System Modeling | User Training | Content Creating

]]>https://devblog.criticalmanufacturing.com/blog/20251202_bom_checklist_material_deviations/Tue, 02 Dec 2025 00:00:00 +0000Romeu Gonçalveshttps://devblog.criticalmanufacturing.com/blog/20251202_bom_checklist_material_deviations/On-the-Fly Adjustments In modern manufacturing, flexibility is key, but it must be balanced with control. That's why our new MES version includes now a powerful new feature: "Material Deviation for Checklist and Bill of Material".

In the industrial equipment industry, it’s not uncommon for operators, during the assembly of parts (guided by a Checklist), to have to make unforeseen changes, such as modifying certain Items of the Checklist or even replacing a component or adjusting the quantity to be used.

BOM - Checklist & Material Deviations Overview

In Critical Manufacturing MES, a BOM can be associated with a Checklist, where each component to be assembled is assigned to specific Checklist Items, ensuring that a defined sequence is followed during the assembly process (Although it's always possible to configure some Checklist Items to be executed at any point during the process) During these operations the end user can on the fly request some changes as shown below:

• Add/Change/Remove Checklist Items
• Add/Change/Remove BOM Items

However, these change requests are not immediately implemented. They need first to be reviewed and either approved or rejected through a Material Deviation protocol. Therefore, this protocol must be also assigned to the Checklist to enable this functionality.

Configuration Highlights

Multiple MES entities contribute to the configuration of this feature, so let's take a look at each of them.

• Bill of Material configuration

Create (or import into MES) the Bill of Material. This entity offers various options, but the most important properties for this use case are the BOM scope, the products with their respective consumption quantities, and the assembly process step."

• Protocol Setup

A protocol of Scope “Material Deviation” must be created to Review and then either approve or reject the changes requested. Its flow chart can be minimal, with a single approval state, or more elaborate with multiple states and approval levels.

• Data Collection and Data Collection Limit Set Optionally, create a Data Collection and a Data Collection Limit Set to capture process data during assembly process

• Checklist Configuration

Create a LongRunning checklist for the material transaction and assign all previously configured entities to it, as illustrated above. For specific Checklist Items, define the components to be consumed during the process, and for others, or the same items, configure the data to be collected

• Context Tables

For the Assembly Step, fill the context tables for BOM, Data Collection and Checklist

Demo

Benefits

CM MES Features like this one bring meaningful benefits across all levels of users in Critical Manufacturing MES:

• Enhanced Flexibility During Assembly: Operators can request changes “on the fly” without completely stopping production, adapting to unforeseen adjustments smoothly.

• Controlled Change Management: All requested deviations are reviewed and either approved or rejected via the Material Deviation protocol, ensuring changes are tracked and authorized before implementation.

• Single GUI for all operations: With the integration of BOMs, protocols, Checklists, and optional data collection, documents and technical drawing, MES users can perform all tasks without switching between different features
  
  

Final Thoughts

The new Material Deviation feature for Checklists and BOMs brings the perfect balance between flexibility and control in modern manufacturing. Operators gain the freedom to adapt to real-world changes on the shop floor, while managers retain oversight and traceability through a structured approval process

Author

Hi! My name is José Romeu Bogas Gonçalves. 😉

I’ve been with Critical Manufacturing since 2018, starting out as an MES Consultant. Earlier this year, I stepped into the recently created Advocate & Architecture team. My role sits at the intersection of technology, communication, and strategy. Making sure solutions are technically sound and that everyone understands how to use or build them.

You can check me on LinkedIn

Skills: MES Consultant | System Testing | System Modeling | User Training | Content Creating

]]>https://devblog.criticalmanufacturing.com/blog/20251104_reusable_spare_parts/Tue, 04 Nov 2025 00:00:00 +0000Romeu Gonçalveshttps://devblog.criticalmanufacturing.com/blog/20251104_reusable_spare_parts/Learn how Critical Manufacturing MES makes tracking, repairing, and reusing spare parts simple and efficient. This blog explains how to manage spare parts in the MES, including sending them for repair to an external supplier or repairing them internally, and then replacing them with other spare parts available in the facility. Any user with the proper permissions can manage and replace a machine's spare parts at any time in an ad-hoc manner. However, it's more common to replace spare parts during the execution of a Maintenance Activity related to the machine.

Introduction

A reusable spare part is a component or part of a machine that, after being removed due to deterioration, failure, or maintenance activity, can be restored or repaired and then used again in the same or another machine.

As an example, let’s take an Asset BOM (also called Equipment BOM) for Wafer Inspection Equipment typically used in the Semiconductor industry.

This equipment has 4 different reusable spare parts that can be replaced at any moment or during a maintenance activity:

• Wafer Stage
• Camera System
• Two Control Centers
• Marking Device

Apart from the reusable spare parts, the equipment also consumes a set of consumables that are used exclusively during maintenance activities. Examples include:

• Air Filter
• Vacuum Pads
• Polyalphaolefin based lubricants

Then

Until very recently, there wasn't an easy way to track and manage spare parts used in the resources (Machines). They were either consumed and therefore removed from the MES system, preventing their reuse, and, in addition, it was not possible to have a clear view of them on the resource. Alternatively, these spare parts could be created as sub-resources and replaced by others when needed, which limited their management for repair or rework and made this process inefficient.

And Now

It's now possible to include in the resources a bill of parts (regardless of whether they are reusable or not). This provides full management of the spare parts and traceability across their entire lifecycle. Taking the Wafer Inspection Equipment

- Because Repairable parts can appear repeated, a designator must be defined. Or these designators can just be used to identify the specific position of a part within the Resource. - During a Maintenance activity the repairable Part must first be removed before a new one can be installed within the machine. Once removed the repairable part can be repaired externally or internally

DEMO

For this demonstration, the machine and the products mentioned above will be used and will already exist in the system. Using all of them a resource list will be created and then Repairable Parts can be managed (inserted, removed and replaced) directly from the Resource. But this is intended for the initial setup. The normal scenario is to replace these parts during maintenance, and this is what will be shown during the second part of the demonstration.

Final thoughts

Managing reusable spare parts effectively is no longer a cumbersome task thanks to Critical Manufacturing MES capabilities. With better tracking and repair options, maintenance becomes simpler and more efficient.

Author

Hi! My name is José Romeu Bogas Gonçalves. 😉

I’ve been with Critical Manufacturing since 2018, starting out as an MES Consultant. Earlier this year, I stepped into the recently created Advocate & Architecture team. My role sits at the intersection of technology, communication, and strategy. Making sure solutions are technically sound and that everyone understands how to use or build them.

You can check me on LinkedIn

Skills: MES Consultant | System Testing | System Modeling | User Training | Content Creating

]]>https://devblog.criticalmanufacturing.com/blog/20251028_rework_limit/Tue, 28 Oct 2025 00:00:00 +0000Romeu Gonçalveshttps://devblog.criticalmanufacturing.com/blog/20251028_rework_limit/Keep rework under control with MES, boosting efficiency and product quality Rework is one of the hidden challenges in manufacturing, affecting costs, efficiency, and product quality. This blog covers how CM MES helps you to control rework, providing solutions to stop errors before they escalate. Beyond rework limits, the other powerful capabilities of our MES are also presented, from real-time visibility to quality enforcement.

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Rework: A short introduction

Rework is the corrective process applied mainly to WIP that doesn't meet the specified quality standard during production. To ensure full traceability, it's usually performed in pre-defined and approved rework flows. For instance, in semiconductor industry, a wafer can be re-coated and re-exposed when photo-resist misalignment or contamination is detected during the inspection.

Besides ensuring traceability and recover value (instead of scrapping the WIP), it also helps to improve yield, customer deliveries and their quality requirements.

Can Rework be done indefinitely and without any control?

Theoretically, yes, if a robust control system is not in place on the shop floor. But we know that neither the customers nor the manufacturers want that. Unlimited rework increases costs and can sometime degrade the quality of the final product, among other issues.

It’s why it may be necessary to restrict the number of times a lot can be reworked due to quality concerns, or even forbidding rework at all. Lots can often only tolerate a limited number of reworks before they become unusable and, in some cases, rework may not be permitted at certain process steps or for specific reasons.

CM MES now provides a mechanism to restrict the number of reworks for materials:

1. Global Limit by Product: Apply an overall rework limit for a specific product.
2. Limit by Step: Define rework limits at specific process steps using a Smart Table
3. Limit by Rework Reason: Restrict reworks based on the reason, using a Smart Table
4. Combination of Limits: Apply these restrictions individually or in combination.

Taking the example above, the lithography process cannot be redone infinitely if misalignment continues to be found at the end of the process. Not to mention the cost of photoresist, labor, and the degradation of reticles, excessive rework can damage underlying layers, and it is better to reject a few misaligned or contaminated dies rather than scrap entire wafers.

---

Another good example happens in medical device manufacturing. In this industry, and especially for specific devices like catheters, rework is very limited or completely prohibited. Catheters come into direct contact with sensitive tissues like vein and urinary tract. Repeated rework can introduce contaminants, which might trigger infections or toxic reactions in the patient.

---

Rework Limits were introduced as an out-of-the-box feature in Version 11.2, but how was it managed in previous version when needed? Well, through extensibility, adding a few configuration tables some attributes and some business rules to implement the required rules. Now, although the situation could be overcome, having custom solutions is always less cost-effective than using out-of-the-box features.

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How MES manages rework limits

In medical industry some products cannot perform rework at all, while others may be reworked but with limits.

For example, after an assembly process, if issues are detected in the component manually assembled, the lot can be sent to rework once to replace the affected components, however, if after the next inspection the same issues are detected again, the lot can no longer be sent to rework to replace the components, and in this case it must be placed on hold or a NCR must be opened.

In the following demonstration, both "Ester IV Catheter" and "Foley V Catheter" products share the same routing. Although rework flows are available, the lots from product "Foley V Catheter" cannot undergo to any rework while the other product may proceed with rework under defined limits.

The following configurations were defined for this demonstration:

Product properties:

Context resolution table configuration:

Here is a demo to show the configurations:

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Rework features available in Critical Manufacturing MES

In addition to rework limits, these are the other available related features

• Simple Design of Rework Flows
  Create and manage rework flows with an intuitive and streamlined approach.

• Integration with Standard Process Steps
  Associate rework operations directly with standard manufacturing steps to ensure full process alignment.

• Configurable Rework Reasons
  Define multiple rework reasons, with the ability to link different rework flows to specific process steps.

• Flexible Return Points
  Configure rework flows to return materials to any designated step within the process flow.

• State-Based Rework Application
  Control when rework can be applied by defining eligible states: Queued, In Process, or both.

• Rule-Based Triggers
  Automatically execute predefined rules when a material is sent for rework — from simple notifications to advanced actions, such as initiating a warehouse transfer request to supply critical Moisture-Sensitive Level (MSL) components required for the rework operation.

• Traceability and Data
  All operations are recorded, and data are available for reports and KPIs.

---

Final thoughts

Managing and Controlling rework is simple with Critical Manufacturing MES. It gives you the tools to prevent errors and improve results.

---

Author

Hi! My name is José Romeu Bogas Gonçalves. 😉

I’ve been with Critical Manufacturing since 2018, starting out as an MES Consultant. Earlier this year, I stepped into the recently created Advocate & Architecture team. My role sits at the intersection of technology, communication, and strategy. Making sure solutions are technically sound and that everyone understands how to use or build them.

You can check me on LinkedIn

Skills: MES Consultant | System Testing | System Modeling | User Training | Content Creating

]]>https://devblog.criticalmanufacturing.com/blog/20250618_enhancing_protocols_with_conditional_flows/Wed, 18 Jun 2025 00:00:00 +0000Romeu Gonçalveshttps://devblog.criticalmanufacturing.com/blog/20250618_enhancing_protocols_with_conditional_flows/How can condition-based Flows enhance or complement the capabilities of other MES entities? This post explores how conditional flows can strengthen the Protocol functionality within the Critical Manufacturing MES environment.

Using flows with conditions, we need to control how far WIP material affected by a protocol is allowed to move through the process. This lets us block shipment or final steps while still allowing earlier operations to continue under controlled conditions.

So, how exactly do Conditional Flows fit into a wider application of protocols? Let’s take a closer look.

Getting Started with Conditional Flow Items

Basic conditional logic can be implemented using simple expressions based on Material (lot) properties or attributes, addressing simple use cases, such as skipping specific Steps or determining the upcoming Flow.

For more complex scenarios, beyond the scope of expressions, Rule Sets can be used to execute advanced decision-making and control logic within the workflow.

Protocol

In a manufacturing context, a Protocol is a predefined process that is triggered when an exception or abnormal condition occurs, such as a defect, an out-of-spec measurement, or a value recorded during in-process inspection that falls outside defined specification limits.

When a Non-Conformance Report (NCR) or a Corrective and Preventive Action (CAPA) is initiated and linked to the affected lots, the system may place those lots on hold, notify the quality team, and — most importantly — prevent them from moving forward to the next operation or being marked as complete (or shipped) until the issue has been fully addressed.

Example:

🧩 Challenge: Since the process Steps preceding Laser Mark do not impact the final outcome of the lots — even when a protocol has been initiated — those lots are allowed to continue through these earlier steps. However, the protocol must be closed before the lots reach the Laser Mark Step, as they could be downgraded and require alternative marking. How can this be implemented?

Here’s how Critical Manufacturing MES handles it in action:

Why This Feature Is So Helpful for Enhancing CM MES

The previous example highlights just a glimpse of what Conditional Flows can achieve. These elements can function independently or enhance other CM MES entities. While the demo focused on material properties, conditions can also incorporate attributes, characteristics, product and product family data, and even specific process step properties.

For more advanced use cases, custom rules can be embedded directly into the Flow structure—enabling dynamic material routing across alternate paths and triggering protocol actions when a lot enters or exits a step.

Final thoughts

To sum up, the use of conditional Flow Items significantly strengthens the CM MES system by enabling dynamic process control and improving overall operational efficiency.

Author

Hi! My name is José Romeu Gonçalves. 😉

I've been with Critical Manufacturing since 2018, starting out as an MES Consultant. Earlier this year, I stepped into the recently created Advocate & Architecture team. My role sits at the intersection of technology, communication, and strategy. Making sure solutions are technically sound and that everyone understands how to use or build them.

You can check me on LinkedIn

Skills: MES Consultant | System Testing | System Modeling | User Training | Content Creating

]]>https://devblog.criticalmanufacturing.com/blog/20250604_smart_routing_for_defect_classification/Wed, 04 Jun 2025 00:00:00 +0000Romeu Gonçalveshttps://devblog.criticalmanufacturing.com/blog/20250604_smart_routing_for_defect_classification/How can condition-based Flows enhance or complement the capabilities of other MES entities? This post explores how conditional flows can strengthen the Material Defect functionality within the Critical Manufacturing MES environment.

By offering a flexible and dynamic solution to route Materials based of specific conditions, conditional Flows serve as a powerful tool for optimizing workflows without the need for extensive custom coding.

So, the question is: how do conditional Flows truly fit into the broader MES ecosystem? Let’s dive in and find out.

Getting Started with Conditional Flow Items

Basic conditional logic can be implemented using simple expressions based on Material (lot) properties or attributes, addressing simple use cases, such as skipping specific Steps or determining the upcoming Flow.

For more complex scenarios, beyond the scope of expressions, Rule Sets can be used to execute advanced decision-making and control logic within the workflow.

Record and Reclassify Defects

The Material Defects functionality is designed to support inspection processes, by enabling the capture of defects — either manually or automatically — during material inspections. These inspections can be performed using dedicated inspection equipment or through visual checks.

This capability is applicable across several industries and process types, but it is especially prevalent in SMT, electronics, and industrial equipment sectors, where individual units are inspected, and defects are logged. Once captured, defects are classified and evaluated. Then, based on the assessment, the units may be accepted, rejected, or routed for repair by the quality team or through advanced inspection systems.

Example:

🧩 Challenge: How can we prevent units with no recorded defects from proceeding to the reclassification step, avoiding unnecessary processing for defect-free units?

Let’s take a quick look at CM MES in action:

Why This Feature Is So Helpful for Enhancing CM MES

The example presented earlier showcases just a fraction of the potential that Flow Items with conditions offer. These elements can function both independently and in conjunction with other CM MES entities. While the demonstrations focused on Material properties, the possibilities extend far beyond this. Attributes and characteristics of Materials along with Product properties, Product families, and process Steps, can all be incorporated.

In more complex scenarios, custom rules can be developed and integrated into the Flow structure. This flexibility also supports dynamic routing, allowing Materials with defects to follow alternate paths and triggering specific rules when a lot enters or exits a Step.

Final thoughts

In conclusion, the adaptability of condition-based Flows allows CM MES to respond intelligently to material-specific data, such as defects, optimizing process paths and improving operational effectiveness.

Author

Hi! My name is José Romeu Gonçalves. 😉

I've been with Critical Manufacturing since 2018, starting out as an MES Consultant. Earlier this year, I stepped into the recently created Advocate & Architecture team. My role sits at the intersection of technology, communication, and strategy. Making sure solutions are technically sound and that everyone understands how to use or build them.

You can check me on LinkedIn

Skills: MES Consultant | System Testing | System Modeling | User Training | Content Creating

]]>https://devblog.criticalmanufacturing.com/blog/20250521_aql_inspection/Wed, 21 May 2025 00:00:00 +0000Romeu Gonçalveshttps://devblog.criticalmanufacturing.com/blog/20250521_aql_inspection/How can condition-based Flows enhance or complement the capabilities of other MES entities? This post covers the use of conditional flows to address out-of-the-norm cases in AQL inspection

Quality control in manufacturing often relies on standard procedures—but not every situation fits the mold. When exceptions occur, systems need to adapt. In this post, we explore how Conditional Flows can handle these cases with flexibility and precision.

Getting Started with Conditional Flow Items

AQL Inspection

AQL Inspection Standards

Watch how CM MES makes it simple:

Why This Feature Adds Real Value to CM MES:

Final thoughts

Author

Hi! My name is José Romeu Gonçalves. 😉

I’ve been with Critical Manufacturing since 2018, starting out as an MES Consultant. Earlier this year, I stepped into the recently created Advocate & Architecture team. My role sits at the intersection of technology, communication, and strategy. Making sure solutions are technically sound and that everyone understands how to use or build them.

You can check me on LinkedIn

Skills: MES Consultant | System Testing | System Modeling | User Training | Content Creating

For more complex scenarios, beyond the scope of expressions, Rule Sets can be used to execute advanced decision-making and control logic within the workflow.

Once the process is stable, it typically runs with minimal concerns. However, when new products are introduced or changes in consumables, durables, or equipment occur, it is common - despite prior engineering validations - for a limited number of units to be sent ahead during a transitional phase.

This practice helps confirm that the results align with expectations before proceeding with the remaining lot and moving into full-scale production.

This approach is known as a Send-Ahead Run in CM MES, and often referred to in the semiconductor industry as a golden wafer or golden sample.

🧩 Challenge: The SAR Validation step is required only for the Send-Ahead wafer to capture the results, while all other lots must bypass this step. How can this be achieved?

In the demonstration, only Material properties were used in the expressions, however, the possibilities extend far beyond that. Attributes and characteristics of Materials, as well as properties of Products, Product families and process Steps, can also be incorporated.

For more complex scenarios, custom rules can be created and embedded within the Flow structure. This functionality also enables the dynamic routing of Material through alternate Flows and can trigger specific Rules when a lot enters or exits a Step.