Eliminate Human Errors — AiRPA Delivers 99.9% Recording Accuracy on Packaging & Testing Lines

 

At a leading global provider of semiconductor packaging and testing services, production teams handle billions of test data points daily and perform quality grading on millions of chips. Despite a high level of automation, many key processes still rely on manual operation and data logging, limiting efficiency and increasing the risk of human error.

With rising demands for faster delivery and higher quality, accelerating response time and reducing manual workload have become essential. Implementing non-intrusive, real-time data collection and automated workflows is a critical step in the company’s digital transformation journey.

 

 

Challenges

  • Heavy reliance on manual data entry：Each test cycle generates large amounts of data. Operators must copy down data from equipment screens and manually input it into reporting systems, which is time-consuming and prone to omissions and errors.

  • Delayed error response：Engineers must go on-site to check and resolve issues. With test stations spread out across multiple areas, downtime is lengthened and production output reduced.

  • Fragmented test workflow：Processes like testing, calibration, data recording, and report generation are not unified in a single system, relying on manual coordination and limiting efficiency.

  • High implementation barriers：Traditional automation solutions often require changes to existing hardware or software, with high costs and risks that hinder large-scale deployment.

 

 

 

Solution

To overcome production bottlenecks, the company implemented Accordance’s AiRPA robotic process automation system. This non-intrusive solution was deployed on existing test stations to quickly enable data capture and workflow automation.

  • Real-time Screen Capture + Text Recognition：Edge modules capture screen images in real-time and extract test values automatically using OCR, eliminating the need for manual transcription.

  • Automated Workflow Scripts：Scripts based on the standard operating procedure automatically retrieve data and upload it to MES via SECS/GEM communication protocol.

  • Accelerated Maintenance Response：Real-time error detection and instant alerts significantly reduce issue response and repair times.

  • Non-Intrusive Architecture, Fast Deployment：No changes to existing hardware or software are required, allowing rapid deployment without disrupting operations.

 

 

 

Advantages & Results

 

  • Automated Data Capture — 65% Reduction in Manual Workload
    By leveraging screen capture and OCR technology, test data is recorded automatically, replacing manual transcription and consolidation, improving accuracy and reducing labor requirements.
  • Real-Time Error Handling — 75% Faster Response Time
    When errors occur, engineers receive instant notifications and can troubleshoot remotely, significantly reducing production downtime.
  • Rapid Deployment, Seamless Integration — Just 1–2 Days per Station
    The non-intrusive design integrates easily with existing equipment, requiring no changes to system architecture or production downtime, enabling quick, large-scale adoption.
  • High Scalability — Compatible with Diverse Equipment & Environments
    The solution is compatible with various brands and models of test equipment and is independent of existing system structures, making it easy to scale across multiple factories.
  • Low Cost, High ROI — One-Time Purchase with No Licensing Fees
    No subscription or ongoing maintenance costs, enabling budget-friendly digital transformation and station-by-station implementation.