60% Efficiency Boost! PLC+ Unlocks New Momentum for Semiconductor Packaging and Testing Lines

 

As manufacturing processes become increasingly complex, semiconductor packaging and testing plants face challenges such as managing massive amounts of manufacturing data and achieving greater equipment efficiency. In particular, the legacy PLC equipment still widely deployed on production lines often lacks communication and integration capabilities, which makes it difficult to respond to errors in time and utilize data effectively. Under pressure to increase capacity and improve quality, assembly and testing plants require a data networking solution that can be quickly implemented with minimal disruption to accelerate the digitalization of outdated equipment and inject real-time responsiveness and proactivity into production line management.

 

 

Challenges

  • No Remote Monitoring — Onsite Troubleshooting Required：Legacy PLCs lack connectivity, forcing engineers to handle issues onsite, which delays repairs and recovery.

  • Dispersed Data—Time Consuming to Log Manually：Operators manually record and compile equipment data, which is inefficient and has a greater risk of mistakes.

  • Complex System Architecture—Difficult to Integrate：PLCs from different manufacturers and utilizing different protocols are deployed across production sites and lines. Without a centralized display and operating platform, engineers cannot make real-time adjustments to equipment.

 

 

 

Solution

With the PLC+ Remote Control and Data Collection solution, enterprises can seamlessly connect legacy PLC systems without altering existing equipment, enabling real-time monitoring and automated data upload for smarter operations.

  • Non-Intrusive Integration with Existing PLCs：The PLC+ connects directly to existing equipment without modifications to the hardware architecture. Multiple communication protocols are supported, including Modbus TCP, OPC, and MQTT.

  • Real-time Data Collection and Upload to MES:：Automatically collect and upload equipment data to MES in real time, replacing manual entry and reducing human error. Two-way communication can also be implemented, enabling real-time verifications of process data.

  • Reduce Manual Inspections and Increase Efficiency：Decrease the need for onsite monitoring, allowing personnel to focus on higher-value tasks and improve labor efficiency.

  • Scalable & Site-Friendly：Modular architecture allows PLC+ deployment to be easily copied and scaled across multiple sites and production lines.

 

 

 

Benefits & Results

  • Lower O&M Costs — 60% Less Manual Labor
    Remote control capabilities reduce the need for onsite presence, decreasing labor demands and operational risk.
  • Remote Intelligent Control — 70% More Operational Flexibility
    Users can emulate HMI signals and remotely issue commands to adjust PLC parameters, enabling comprehensive smart control, increasing efficiency and ease of operations.
  • Flexible Digital Transformation—Cross-Industry Applications
    The PLC+ can be adapted to various environments including electronics, semiconductor, and chemical manufacturing, realizing more efficient, more intelligent automated management.
  • Revive Legacy PLCs — High ROI, Low Cost
    Enable smart upgrades without replacing legacy PLCs, reducing upgrade time and saving costs.