Smart Systems

“Network in the spotlight”: When machines listen – How acoustic analyses prevent downtime in semiconductor production

June 10, 2025. In the highly complex world of modern semiconductor factories, every second counts. Together with partners such as GlobalFoundries, ZEISS Digital Innovation and DELTEC electronics, the Smart Systems Hub has developed a solution that addresses precisely this issue: With the help of IoT sensor technology, machine learning and edge computing, the Acoustic Analyser detects wear and tear on automated transport systems at an early stage – before expensive failures occur. What makes it special: The innovation was not created in the laboratory, but directly in a co-innovation format – from the initial idea in the Digital Product Factory to successful implementation in the cleanroom.

Eine IoT-gestützte Lösung soll den Verschleiß automatisierter Transportsysteme in Halbleiterfabs überwachen. Foto: Smart Systems Hub

The Acoustic Analyser – IoT meets predictive maintenance

One of the key technical developments in this project is the Acoustic Analyser from DELTEC electronics. This innovative sensor system monitors acoustic signals from overhead vehicles (OHVs) that transport wafers within production. The system uses precise sound analysis to detect unusual noise patterns that may indicate mechanical wear or malfunctions.

How the Acoustic Analyser works:

Ultrasonic sensors detect the approach of the OHVs.
The sounds of the transport trolleys are continuously recorded.
The acoustic data is sent in real time via WLAN to a central evaluation platform.
Machine learning algorithms analyze the data and detect deviations.
The maintenance team is automatically notified if any anomalies are detected.

This early detection of defects prevents unplanned downtime and ensures a smooth production flow.

Co-Innovation in action – from MVP to production solution

The foundation stone for this project was laid in the Smart Systems Hub’s Digital Product Factory. This is where an initial minimal viable product (MVP) was created to record mechanically induced signs of wear on the OHVs. On this basis, the Heimdall implementation project was launched with the aim of transferring the solution to the real production environment.

The Smart Systems Hub played a key role in this: from conception to technical realization and implementation in the cleanroom, agile development approaches were combined with industrial excellence. The result was:

A scalable IoT infrastructure for real-time data analysis
An enhanced dashboard for maintenance teams
The integration of new optical sensors to increase diagnostic accuracy
An AWS-based software architecture, that manages and evaluates all sensor data

Edge computing for maximum efficiency

A crucial aspect for implementation in production is efficient data processing directly on site. Edge computing calculates the health score of each individual OHV directly at the sensor, minimizing the network load and optimizing response times. This makes the solution not only powerful, but also highly scalable.

Next steps – From the factory to the market

The Heimdall project is a prime example of successful co-innovation: close collaboration between technology providers, industrial companies and digital experts has made it possible to create a smart solution that not only revolutionizes existing maintenance processes, but also sets new standards for industrial automation.

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Our “Network in the Spotlight” series offers insights into collaborations, partnerships and co-innovation processes and thus into the joint development of exciting and innovative products, services and solutions in Silicon Saxony.

Are you also part of a joint or co-innovation project? Then send us an email to redaktion@silicon-saxony.de or contact our editor Robert Krauße by phone (+49 351 8973-3866). Together we will publish your network story.

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