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End-to-End Obsolescence Controller Solution for a Semiconductor OEM

Obsolescence Controller
End-to-End Obsolescence Controller Solution for a Semiconductor OEM

Client

Leading Global Semiconductor OEM 

Services

  • Legacy HW Re-Engineering
  • Embedded System Design
  • Compliance & Validation

Tools

  • Custom I/O Boards
  • Firmware Development
  • Multi-Protocol Interfaces
  • Testing & Compliance Tools

Results

  • Form-Fit-Function Replacement for 4 I/O Configurations
  • Tool-level Test Passed at Customer Site
  • Currently Undergoing Reliability Testing

Customer Background

Our client, a prominent global semiconductor equipment manufacturer, faced an urgent challenge due to the obsolescence of a critical I/O Controller. This controller played a vital role in operating semiconductor tools by managing analog, digital, Ethernet (IP/TCP), and fiber optic interfaces. The discontinuation of this component posed a significant risk to ongoing operations, tool availability, and long-term maintenance.

Project Overview

The primary objective was to develop a fully compatible form-fit-function replacement for the legacy controller, capable of supporting four distinct configurations. The replacement had to integrate seamlessly with the existing tool infrastructure while meeting all required functional, electrical, and regulatory compliance standards.

Challenges Faced

Hardware Obsolescence: The original legacy controller was discontinued, and replacement parts or OEM support were unavailable.

System Complexity: The controller needed to support a mix of analog, digital, Ethernet, and fiberoptic interfaces.

Compliance Requirements: The redesigned controller had to meet industry-standard EMC and safety certifications.

Integration Constraints: The new solution had to retain the mechanical footprint and electrical interface of the original to minimize redesign at the tool level.

Our Comprehensive Approach

System Reverse Engineering
  • Analyzed the original legacy controller within a lab setting to understand system architecture and communication protocols.
  • Evaluated next higher-level assemblies to document I/O behavior, power requirements, and interface dependencies.
System Reverse Engineering
System Architecture and Requirements
  • Created a comprehensive system block diagram outlining subsystems and communication flows.
  • Defined detailed hardware and software requirements, including functional and compliance specifications.
System Architecture and Requirements
Hardware and Mechanical Design
  • Captured schematics and designed new PCBs using modern components and form-factor matching.
  • Performed ERC and DRC checks to validate the design prior to development.
  • Designed a new mechanical enclosure compatible with legacy mounting and tool layout.
Hardware and Mechanical Design
Firmware and GUI Development
  • Developed embedded firmware from scratch to manage all I/O types and interface protocols.
  • Created a graphical user interface (GUI) for system diagnostics, configuration, and monitoring.
Firmware and GUI Development 
Testing and Compliance
  • Conducted modular testing, followed by full system integration and bench-level validation.
  • Executed pre-compliance testing for EMC performance and coordinated with external agencies for formal EMC and TUV certification.
  • Provided a tool-level test plan and engineering documentation for system release and integration.
Testing and Compliance 

Execution Roadmap

Phase 1
Controller Analysis

Reviewed obsolete legacy controller board design and its electrical interactions within the system.

Phase 2
Requirements Definition

Captured detailed functional and interface specifications based on tool-level requirements.

Phase 3
Hardware and Firmware Development

Designed and developed a re-engineered board with firmware and GUI support.

Phase 4
Integration and Testing

Completed full system-level testing and validated the solution against live tool operations.

Phase 5
Compliance and Reliability Validation

Supported external certification tests and initiated ongoing reliability trials.

BeforeAfter

Results and Business Impact

Seamless Tool Integration

Seamless Tool Integration

The new controller was successfully integrated and passed tool-level validation at the customer site.

Future Flexibility

Future Flexibility

The controller design accommodates four legacy configurations, ensuring broader applicability.

Lifecycle Extension

Lifecycle Extension

Enabled continued use of existing semiconductor tools, avoiding costly replacements.

Ongoing Reliability Testing

Ongoing Reliability Testing

Currently undergoing extended field validation to certify long-term deployment readiness.

Operational Continuity

Operational Continuity

Eliminated risks associated with obsolete hardware.

Key Benefits Achieved

Full form-fit-function

Full form-fit-function compatibility with original controller
Enhanced in-house Capability

Enhanced in-house capability for legacy system support
Modernized system architecture

Modernized system architecture using up-to-date components
Compliance with industry safety and EMC standards

Compliance with industry safety and EMC standards
Reduced downtime risk

Reduced downtime risk through proactive re-engineering