High-Tech Production Line

Solutions Guide
Contents

High-Tech Manufacturing 1

2 Challenges for Solutions Implementers

Trends in High-Tech Production Lines 3 Industry 4.0 Moves from Concept to Reality

4 Demand for Optimized and Automated Production

4 Drive for Increased Security

ATEN Solutions for Production Lines 5

Key Advantages 6

ATEN High-Tech Production Line 9 Remote Monitoring and Control Clean Room + Control Room, Taiwan
Solutions in Action 11 API for Automation and Data Collection Automated Semiconductor
Production Line, Taiwan

13 Electronics Testing and Quality Control Electronics Manufacturer, USA

15 Remote Operations and IT Maintenance Manufacturing Production Line, UK

17 Critical Monitoring and Control Panel Fabrication, South Korea

19 Critical Monitoring and Quality Control in 4K Standards Testing for

Automotive Industry, USA
High-Tech Manufacturing
Manufacturing is among the vertical sectors to have received the largest impact
of the technological developments of the last decade. Beyond the incredible
cross-industry disruption created by the Internet of Things (IoT), new paradigms
in consumer purchasing behavior, manufacturing services, and industrial security Challenges for Solutions Implementers
are beginning to upend traditional production models, leaving companies both
large and small scrambling to catch up to ensure competitiveness. • Long Distances + Legacy Equipment
In a large-sized facility such as a semiconductor fabrication plant (fab), distances between individual
The Evolution of Scale and Complexity
production areas can be very long, making it inefficient to travel between and monitor each line individually.
As new market demands created by these technologies grow, manufacturing In addition, legacy production line equipment that is too expensive to replace may offer no Internet connection.
facilities need to evolve both in terms of the scale and the complexity of their
operations. In some industries, this can represent an expansion of physical
• Clean Room Requirements + Limited Access
production capabilities, with some companies building facilities that may occupy a These advanced facilities present another unique difficulty – the high-precision wafer manufacturing
space the size of a small town. In other cases, it’s a matter of enhancing the process requires a perfectly clean, sterile environment, making it hard to enter and leave the fab
density and complexity of the technology integrated on the production line. frequently to check the machinery.

Production of advanced technologies, such as semiconductors, has borne the

• Management Integration + Flexible MES
brunt of this disruption more deeply than traditional industries due to demands for Efficiency and quality control as the result of a well-implemented and flexible manufacturing execution
strict environmental controls and manufacturing precision all the way down to the system (MES) is also essential for improved production results and reduced manufacturing costs. But if
microscopic level. too much testing equipment needs to be integrated on the line, management becomes a problem. That’s
why integrating test equipment and high-efficiency management solutions to perform the various
The mutual implications of size and complexity are requiring new and innovative testing procedures can yield enormous benefits.
connectivity solutions to support development in this constantly evolving industry.
• Control Prioritization + Emergency Response
Also vital is prioritized control of key equipment on the production line with different levels of control
for different users, such as view-only or full control for administrators. What’s more, the lack of local
priority restricts on-site operators from taking control during an emergency.

• Network Performance + Security

Additionally, the need to install software on both the local and remote PCs will affect those PCs'
performance and network bandwidth. Some manufacturers are wary of VNC (virtual network computing)
solutions since the system’s resources will be occupied, meaning data security is not assured. This makes
a KVM solution using the existing company Ethernet the ideal choice in this kind of environment.

To meet the demands of the wide variety of high-tech production environments and increase production
line efficiency, ATEN has developed a series of KVM over IP solutions that provide convenient, flexible,
and efficient management of production control systems and quality-testing operations.

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Trends in
High-Tech Production Lines

Industry 4.0 Moves from Concept to Reality

Among the many subsets of the Internet of Things (IoT) is the Industrial Internet of Things (IIoT), also referred to as Industry 4.0.
Whereas IoT can cover all devices with embedded sensor technology, IIoT refers specifically to how sensor technology is applied in
industries and how said sensors’ efficiency can bring overarching benefits to the manufacturer and customer alike.

According to an IHS Markit report, worldwide shipments of IIoT devices are predicted to rise to 252 million in 2021, an increase from
99 million in 2016, showing that Industry 4.0 has already grown beyond the conceptual stage and is seeing genuine adoption across
global manufacturing facilities.

High-tech manufacturing facilities are particularly well-positioned to reap the benefits of these advanced analytical processes, with
the constant input of real-time data helping to ensure stable environmental control and prevent against defects occurring during the
production process.

Demand for Optimized and Automated Production

As demand outpaces production speed, optimizing and automating manufacturing processes becomes critical. By 2021, 20% of the
world’s top manufacturers will rely on a secure backbone of embedded intelligence to automate large-scale processes and speed
execution times by up to 25%, according to IDC.

One of the most important things a company looking to optimize its production must do is to make sure its MES is Industry
4.0-ready. This includes being able to process and integrate IoT data, such as making factory-wide operations data available for use
in advanced analytics.

On the hardware side, the role of robotics - which have been used in the industry for decades - will continue to grow as machine
intelligence enhances these robots' capabilities far beyond their present functions and bolsters their role in automated production.
Taking these factors into account, industries will have to significantly increase their technology investments to ensure their MES and
overall production methodology remains efficient enough to stay in the game. This in turn will feed demand for scalable access
management solutions to allow companies to maintain centralized control of an ever-expanding technological infrastructure.

Drive for Increased Security

The benefits of increased industrial connectivity also bring new threats. While most manufacturers are still in the early phases of
implementing IIoT solutions, hackers have already shown a capability for exploiting the vulnerabilities such a system creates.

Even more disconcerting is the overall lack of investment in cybersecurity, which has left the manufacturing industry the second most
vulnerable to attacks after healthcare, according to a report from Manufacturing Business Technology.

However, as the industrial sector grows increasingly aware of these profound dangers, we will see a new drive among manufacturing
facilities to seek out solutions that provide essential performance-enhancing, cross-factory connectivity while not putting vital
operations data at risk. Therefore, the need for solutions with improved security means we will continue to see updating of legacy
KVM equipment in this segment.

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ATEN Solutions for High-Tech Production Line
Production Lines Key Advantages
ATEN specializes in the design and manufacture of high-performance KVM as Remote Control & Monitoring Remote Management Power for Priority Control for Safe, Flexible
(RCM) management solutions, helping its customers to improve efficiency, centralize management, and maintain
Real-Time Control Supervision
safe operations in high-tech production line environments such as semiconductor foundry, assembly, and testing.

Our KVM over IP series of solutions can provide the following benefits: • ATEN KVM over IP solutions put supervisors and operators in • ATEN solutions offer priority control of remote and local operations
complete control of all production equipment connected to over in a center of manufacturing, ensuring that control of your
• Reduce frequency of entering the production line / clean room IP devices no matter where they are deployed. production line equipment is always in the correct hands.
• Panel Array Mode™ to monitor multiple machines at once • Our solutions allow you to eliminate the distance restrictions of • KVM over IP switches work with the access control box in the
• Immediate emergency response / alarm monitoring production line management, allowing centralized real-time production line, allowing instant local over remote prioritization to
• Instant prioritization control operation and maintenance and enabling a faster response take over control to ensure operational accuracy and to handle errors.
• Secured authentication and authorization protocols to emergencies. • Solutions provide prioritized control of key equipment on the
• Open APIs for software integration • Diversified port operation mode enables flexible remote access for production line with different levels of control for different users.
• No impact on machine system performance production line operators with Occupy, Exclusive, and Share modes.

ATEN’s Three Kinds of Solutions

Efficient Operations for Simplified Secured Data for No Risk + Zero

1 Remote Management
Solution
For simple remote management
2 Real-Time Monitoring
Solution
For remote control & monitoring
Management Impact on Performance

• Panel Array Mode™ allows production line administrators to • Our KVM over IP solutions for production lines increase security and
display the video output of up to 64 servers on their monitors at reduce risk by utilizing the industry's highest security authentication
the same time, dramatically increasing efficiency, especially for and encryption standards and protocols.
equipment testing. • ATEN offers remote management of your production facility’s entire
• A user-friendly toolbar within the KVM user interface provides IT infrastructure without the use of VNC software, further ensuring
convenient management through configurable function icons. the security of your data, with zero impact on your production line
KVM over KVM over Access • Broadcast Mode allows the installer to simultaneously handle and PC’s performance and bandwidth.
IP Switch IP Switch Control Box copy actions to all computers at once. Keyboard input, mouse
input, or both, can be broadcast across multiple PCs or Macs
simultaneously, instead of weaving between all the PCs.

Remote KVM KVM Sharing Remote KVM KVM Sharing Video

Console Device Console Device Distribution

Scalable, Customizable for Superior Video up to 4K for Seamless

Future-Proof Solutions Visual Experience

3 API for Automation

Solution
For automatic management and data collection
KVM over
IP Switch API
• Our extensive line of over IP KVM switches provides flexible,
scalable solutions ensured to future-proof your high-tech
production line environment against changes such as additions of
• High-definition images up to 4K make ATEN KVM over IP solutions
an excellent choice for production environments in which high
resolution monitoring is required.
newer manufacturing equipment. • ATEN’s unique Auto Signal Compensation (ASC), Real Visual
• Customized APIs for software integration applications and compression, and patented Deskew technologies correct signal
automated actions. distortions that occur over long distances to provide clear, sharp,
Access Control Remote KVM KVM Sharing Video • Cascading and daisy-chaining allows for a fully scalable KVM optimized video to remote displays to avoid impairment of the
Box Console Device Distribution production line management solution that grows in step with operator’s experience.
your business.

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ATEN High-Tech Production Line
Solutions in Action
01 Remote Monitoring and Control
02 API for Automation and Data Collection
03 Electronics Testing and Quality Control
04 Remote Operations and IT Maintenance
05 Critical Monitoring and Control
06 Critical Monitoring and Quality Control in 4K

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 Challenges Solutions

• Increase management efficiency across multiple Provides complete system management across different
facilities while reducing the amount of facilities and reduces number of operators while also providing
operators to help keep costs down the ability to monitor every machine’s status and scheduling

• Need remote access to the complete system but Can remotely perform machine testing, adjust parameters,
also to reserve control ability and priority and implement emergency shutdowns while also reserving
settings to original production line server priority control in the clean rooms

• Need to monitor and share an ever-expanding Remote console content is displayed on the control room video
amount of video and data streams wall for efficient collaboration and effective decision making

• Ensure system security by providing a non Leverages existing IT network environment with lower cost
software-based centralized management solution and better anti-interference ability

KN4116A KA7171A VM3200

16-Port Cat 5 KVM over IP Switch with Virtual Media KVM Adapter Module with 32 x 32 Modular Matrix Switch
Local Console

Prototype

01 Remote Monitoring and

Control

Clean Room +
Control Room, Taiwan

Remote Monitoring and Control

In addition to it being highly inconvenient to get in and out of clean room production environments, in large-sized manufacturing
facilities with vast floor areas, distances between individual production areas can be so huge that it is virtually impossible to
physically monitor each line individually. This, along with the inconvenience and wasted effort of constantly moving from one
industrial PC to another as well as the costs of purchasing a separate keyboard, mouse, and monitor for each computer, adds up
to high costs in terms of both technology and personnel. Furthermore, control rooms for remote monitoring purposes can be
hindered by solutions that do not provide suitable conditions for effective troubleshooting and fast decision making.

Multiple Clean Room Environment with Control Room, Taiwan

A high-end manufacturing company had a huge facility area with multiple clean rooms that made running physical maintenance
both time-consuming and costly, so they required a remote monitoring solution that provided complete system management
across all facilities and significantly lowered response times. They also needed a control room that facilitated efficient remote
troubleshooting by allowing remote admins to log into the same servers at the same time.

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 Challenges Solutions

• Requires a secure solution that can process Provides security and reliability as there is no data transfer
KVM information and correctly identify between the manufacturing machines and the KVM over IP
production information feedback
Provides APIs for software integration applications while
• Needs to integrate with MES and to facilitate OCR solution directly captures the device display screen data
data collection for analysis and collects the data for analysis

• How to replace human operation Provides APIs for HMI operation by software program for
automated actions
• No impact to the production line utilization
Hardware architecture does not impact or reduce system
performance of the production line machines

KN4116A CS231 API

16-Port Cat 5 KVM over IP Switch with Virtual Media USB VGA Computer Sharing Device

API

02 API for Automation

and Data Collection

Automated Semiconductor
Production Line, Taiwan

API for Automation and Data Collection

Production line automation faces many challenges, from data collection and checking data accuracy, to recipe automation and
error detection. In many cases, it is not only difficult to identify production information feedback, but also to assess the type of
system warning, while the manual selection of recipes are prone to human error. Before OCR automation, service operations had
to be performed manually by operators who needed to suit up and enter the fab, and errors had to be confirmed by manual
inspection. These situations require solutions that allow machine information data to be effectively identified in an automated
process for analysis to be carried out, and errors to be processed automatically and immediately, while also improving equipment
utilization rates and preventing human operation error.

Automated Semiconductor Production Line, Taiwan

A manufacturer wanted to install a new automated control solution that would integrate with its production line MES and perform
checks and corrections for tests, emergency handling, automatic run recipes, data collection, and keep system logs. Its running
production equipment does not support open Application Program Interfaces (APIs), while an installed software would use too
much of the machine’s system resources and impact utilization rate. Even machine vendors do not provide this kind of upgrade.

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 Challenges Solutions

• Must provide on-the-fly visibility into the status Remote BIOS-level access allows instant visibility for
of each product on its test rack with capability troubleshooting without disturbing local console technicians
for remote operation for BIOS-level access
Panel Array Mode allows support personnel to monitor the
• Provide ability to selectively and intuitively video output of up to 64 servers on one screen simultaneously
monitor attached servers
Users are able to launch multiple Virtual Remote Desktops to
• Need to conduct hundreds of server tests from control multiple connected servers from the same login session
remote desktops without impacting
system performance Over IP access means there is no longer any need to
physically move their legacy KVM solution to each malfunc-
• Reduce wait time on each test rack and address tioning unit, reducing machine wait time without sacrificing
machine status immediately quality of the testing procedure

KN2116VA CC2000
16-Port Cat 5 KVM over IP Switch with Virtual Media Centralized Management Software

03 Electronics Testing and

Quality Control

Electronics
Manufacturing, USA

Electronics Testing and Quality Control

Engineers assembling a system for electronics testing and quality control have to ensure that said system can guarantee that all
products are built to exact specifications. This means that all racks in the testing environment must have the ability to operate,
configure, and test every available computer and software platform before being shipped. While getting devices through the
configuration process can be time consuming, and reducing machine wait time without sacrificing quality of the testing procedure
is vital, engineers must also grapple with the challenge of products being tested in multiple labs in different locations. This
necessitates KVM solutions that allow for remote operations along with the ability to monitor the status of all products being tested.

Electronics Manufacturer, USA

This company is a global provider of products, services, and solutions to industrial and commercial users of electronic components
and enterprise computing solutions. They serve as a supply channel partner for more than 900 suppliers and 125,000 original
equipment manufacturers (OEM), contract manufacturers and commercial customers through a global network of more than 310
locations in 51 countries and territories. They were looking for a solution that allowed engineering support personnel to perform
troubleshooting on all of the units being tested on the rack without interrupting the technician at the local console or
compromising the integrity of the testing.

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 Challenges Solutions

• Needed a convenient and secure solution to ATEN KVM over IP Console Station Series provides dual-view
enable constant monitoring of server status display for both monitoring and broadcasting commands
when broadcasting commands
Broadcast Mode allows the installer to simultaneously
• Provide process enhancement to shorten the handle and copy actions to all computers at once
time to install and update a large amount of
PCs and servers Panel Array Mode allows support personnel to monitor the
video output of up to 64 servers on one screen simultaneously
• Provide ability to selectively and intuitively
monitor attached servers PadClient app allows swift surveillance and access to the
servers via KVM switches
• Required OS flexibility and accessibility to a
variety of operating systems while on the go

KN2124VA KA8288
24-Port Cat 5 KVM over IP Switch with Virtual Media Dual HDMI KVM over IP Switch Console Station

04 Remote Operations and

IT Maintenance

Manufacturing
Production Line, UK

Remote Operations and IT Maintenance

Speeding up operations and improving troubleshooting efficiency in a manufacturing environment is not only related to
emergencies. While remote operation solutions can help to remove the need for troubleshooting personnel to be constantly
present on the factory floor, there are day-to-day operations where centralized remote access can also be a great advantage. For
example, IT managers in production line environments are often required to configure and set up many computers with repeat
keyboard/mouse operations for mass deployment or refurbishing computers, which is time consuming and frustrating. Solutions
that boost efficiency in this area must be able to broadcast keyboard input, mouse input, or both, across multiple PCs or Macs
simultaneously, instead of weaving between all the PCs. Further requirements are keyboard macro features that allow IT staff to
record their own keyboard macros and recall the functions with hotkeys to increase work efficiency.

Manufacturing Production Line, UK

A large manufacturing company needed a way to not only selectively and remotely monitor multiple production line servers but also
to quickly and easily maintain and update them. The servers were positioned at various locations across the large manufacturing
facilities. With up to 16 simultaneous computer installations required per individual production line, the solution needed to be able
to send installation steps to each of the computers using files taken from a central storage system. It was also required that if
something were to happen on a specific server, the operators would be able able to view and act upon it immediately by taking
control from wherever they are.

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 Challenges Solutions

• Supervisors needed remote access to highly Remote access allows instant visibility for supervisors
expensive production line equipment over the
network to support 3 shifts of full-time Provides ability for remote engineers to take remote control
24/7 operators of non-staffed areas and the access control box with priority
access when needed
• Priority control for remote and local
operations required Remote engineer can monitor four browsers on one screen
via Web-based GUI
• Required a Web-based monitoring system with
advanced functionalities KVM over IP solution takes up minimal space while allowing
for experienced engineers to set up new production lines
• Must minimize space requirements and more efficiently
maximize personnel efficiency

CN8000A
Single Port VGA KVM over IP Switch

05 Critical Monitoring
and Control

Panel Fabrication,
South Korea

Critical Monitoring and Control

Critical monitoring concerns are challenging because supervisors and remote engineers need to take remote control of non-per-
sonnel areas and provide support for field engineers. Solutions that provide customized firmware to work in conjunction with
access priority components can help to prevent accidents in these situations. Another issue that engineers must consider is that
system resources might be occupied, which can create a data security issue if a software solution such as VNC is enabled. It’s up
to engineers to incorporate a KVM solution that provides critical monitoring and control along with secure access and high
quality data throughput between the consoles and analytical servers over extended distances that also incorporates emergency
access prioritization.

Panel Fabrication, South Korea

A global manufacturer of LCD panels has several manufacturing and module assembly plants. The production equipment is
extremely expensive and requires 3-shift engineers for full-time operation, with two engineers handling the control system for
individual equipment, one in the fab clean room doing field operation and another in the control room doing remote monitoring.
The supervisor needed a solution to provide them priority access, allowing them to take remote control of areas without staff.

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 Challenges Solutions

• Consolidate remote monitoring and remote Provides remote access and remote monitoring and
control methods for various types of analytical prioritization control methods for multiple stations with
servers with access control IPCs running as analytical servers

• Required low-latency monitoring at 4K resolutions Supports UHD video quality – up to 3840 x 2160 @ 30Hz for
critical monitoring
• Secured and controlled access to every server
for control room supervisor to ensure Four access modes of permission on transmitters ensures
internal compliance complete security

• Access to every server needs to be logged and CCKM Management Software provides detailed access
recorded to ensure tests are not compromised information, while each operator can only access their own
dedicated servers

KE8950 2XRT-0015G
KVM over IP Matrix System Access Control Box

06 Critical Monitoring and

Quality Control in 4K

Standards Testing for

Automotive Industry, USA

Critical Monitoring and Quality Control in 4K

For production environments in which high-resolution monitoring is required, 4K over IP solutions can be an excellent choice. For
example, automotive production companies need to invest heavily in their IT infrastructure to provide operators with ultra-high
resolution, low-latency monitoring and access to every analytical server, allowing them to ensure internal compliance at all times.
Creating a system integrating consolidated, remote, multi-operator access for various types of analytical servers without loss of
video quality is an engineer’s most important responsibility in this environment. Often, each operator needs to have access to
only their own dedicated servers to avoid tarnished results, meaning that test reports and record logs of the testing procedure
remain uncompromised. Solutions also need to provide access to servers from many locations, including different testing rooms
and overseas facilities.

Standards Testing for Automotive Industry, USA

A leading car manufacturer in the UK relies heavily on high-end analytical systems to ensure every vehicle is compliant with the
emissions targets in each export market. The company therefore needed a solution that would allow them to consolidate remote
monitoring and control of the different system servers while providing secure access to help prevent mistakes during the testing
process. It also had to provide high-resolution monitoring with low latency.

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Simply Better Connections

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About ATEN
ATEN International Co., Ltd., established in 1979, is the leading provider of AV/IT connectivity and management solutions. Offering integrated KVM,
professional AV, and intelligent power solutions, ATEN products connect, manage, and optimize AV/IT equipment in corporate, government, education,
broadcasting and media, and transportation environments. ATEN has 570+ issued international patents and a global R&D team that produces a
constant stream of innovative solutions, resulting in a comprehensive portfolio of products available worldwide.

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