When a global manufacturer sought to improve the efficiency of its wafer handling system, they turned to Boston Engineering to uncover hidden bottlenecks and unlock faster cycle times. Through a precise, data-driven latency analysis, Boston Engineering delivered a solution that not only boosted performance but did so with zero added risk.
The focus and discipline of DFX is a powerful tool if used as part of a broader strategic approach to developing product/process differentiation, and a sustainable advantage against competition. Involve Design for X in Strategy. Once your team has determined the focus of your strategy, place the focus of design on developing competitive advantage.
At Boston Engineering, DFX is a core part of creating values during our product development process. We focus on several key DFX areas that align with our expertise:
Learn more about Design for X (DFX) at Boston engineering: Boston Engineering Design for X
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Wafer handling systems are a crucial link in the semiconductor production chain, responsible for the careful load and unload of fragile wafers during manufacturing. Even slight inefficiencies can add up to significant production delays and lost throughput.
The client’s goal:
Identify and eliminate unnecessary latencies in the load/unload cycle
Improve cycle time without hardware redesign or introducing new risks
Achieve measurable gains in throughput to meet growing demand
Boston Engineering brought a rigorous and innovative approach to the challenge, focusing on a detailed analysis of the wafer handling system's timing. The team developed custom instrumentation (both hardware and software) to break down the operation into measurable events.
Key actions included:
Machine State Time Verification – Created tools to track and timestamp each machine state during the wafer load/unload cycle.
Latency Characterization – Used this data to identify where the system was losing time, often in ways undetectable by traditional analysis.
Pareto Analysis for Optimization – Applied the Pareto principle (80/20 rule) to focus code optimization efforts on the most impactful areas of the system, maximizing return on engineering effort.
Interested in providing your product development team with DFX skills? Learn More about our Applied DFX process and development workshops.
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Boston Engineering’s latency analysis led to immediate and long-term gains:
25% Cycle Time Reduction Identified – Comprehensive analysis uncovered opportunities to cut the total load/unload time by a full 25%.
10% Faster Cycle Time Implemented Immediately – Through targeted software optimizations, Boston Engineering delivered an instant 10% improvement without changing hardware or introducing new risks.
Improved Production Throughput – The acceleration in wafer handling translated directly into increased factory output, helping the client better meet market demand and production goals.
Boston Engineering’s ability to analyze complex system behavior at a granular level allowed the client to unlock hidden efficiency without redesign or risk. This project is a clear example of how targeted software and systems engineering can lead to major performance improvements in semiconductor manufacturing.
Want to accelerate your production without adding complexity?
Boston Engineering helps semiconductor companies identify opportunities for improvement at the system level—whether through latency analysis, automation upgrades, or embedded system redesign. Let’s talk about what’s slowing your process down and how we can speed it up.
In this eBook, we’ll dive into the real-world experiences of DFX subject matter expert John DePiano, exploring the common areas where existing product owners excel, as well as the key opportunities where targeted DFX support can drive major improvements.
Understanding the Importance of a DFX approach
Applying Design for X (DFX) methodologies upfront in product development optimizes the entire lifecycle by improving manufacturability, testability, reliability, usability, and other critical characteristics. This avoids costly redesigns later on, facilitates high-quality products that satisfy customers, reduces manufacturing and service costs, and supports flexibility through modularity and platforms. The holistic perspective of DFX drives efficient, cost-effective delivery of successful products that provide competitive advantage. Investing in DFX early pays dividends across the entire product lifespan.
Do you offer training on DFX for engineering teams?
Education is critical to effectively implement DFX principles. We provide training tailored to your engineers’ roles and product lines. This includes overall DFX methodology, deep dives into specific disciplines like design for reliability or manufacturability, and practical application workshops. Our hands-on approach combines real-world examples and case studies with tutorials on leading DFX software tools. The goal is building organizational DFX expertise and establishing repeatable processes that endure beyond individual projects. Investing in DFX knowledge pays dividends across your entire product portfolio.
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No matter the challenge, our team possesses the expertise in the engineering disciplines and technologies you need to bring your vision to life. Impossible Challenge? Try Us.
Impossible Challenge? Try Us.
Selecting a partner to help you complete your design project is a valuable option to reduce project duration and save money.
The Boston Engineering product development system encompasses DFX to ensure a smooth product launch and success in the marketplace. Boston Engineering has DFX knowledge and experience to address aspects and values of a product such as manufacturability, test, reliability, safety, serviceability, cost, and compliance with industry standards and government regulations.
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