Operator-hours
Every day. That is four full-time operators standing at terminals, waiting.
Axiarete is the application intelligence platform for semiconductor manufacturing. It reads your code, MES models, configurations, logs and tickets; builds a living graph of your digital factory; and turns the software constraints hiding inside your throughput, yield and cycle time into measured, verified fixes — starting with the MES.
For four decades the semiconductor industry has run the most disciplined continuous-improvement program in manufacturing. Every tool has an OEE. Every process has a Cpk. Every excursion has an owner within minutes. The result is the most productive factory floor humanity has built.
But every one of those tools now waits on software. A lot doesn’t move until the MES commits the transaction. A recipe doesn’t run until a control system validates it. A hold isn’t real until it is enforced at the next step. Dispatch, split, merge, track-in, track-out, ship: each is a database write, a business rule, a call chain through code that someone customized years ago and no one has read since.
That software was designed for a different fab: one with headroom, and a full bench of the engineers who built it. Today the same estate carries a demand cycle driven by AI accelerators, high-bandwidth memory and advanced packaging. It supports processes it was never modeled for. It absorbs acquisitions and site consolidations. It answers to a shrinking group of people who understand it. And every AI initiative the fab is betting on — virtual metrology, predictive maintenance, autonomous dispatch — depends on data flowing cleanly through that same estate.
McKinsey estimated that AI and machine learning could eventually add $85–95 billion a year to semiconductor companies’ earnings, against the $5–8 billion they were contributing at the time: less than a tenth captured. The gap is not ambition and it is not budget. It is the digital factory itself.
The manufacturers that lead the next decade won’t just build smarter fabs. They will build smarter digital fabs.
Application delays never show up as downtime. They show up as operator-hours, bottleneck capacity, late holds and burned queue time — spread across sixty thousand transactions a day, where no one is looking.
Every day. That is four full-time operators standing at terminals, waiting.
At the tool you already paid the most for. Capacity you own, spent waiting on a screen.
A hold is only real when it is enforced at transaction time. Every minute of lag between “hold applied” and “hold enforced” is nonconforming WIP still moving through the line.
A stalled lot burns its queue-time budget. A breach means rework, disposition or scrap. An MES outage doesn’t slow the fab — it stops it, and the recovery backlog runs for hours or days.
Change any figure; the results update as you type.
At these numbers, your MES is consuming 33.3 operator-hours a day and 5.6% of your bottleneck tool’s capacity.
These are your numbers, not ours. Bring them to the first call and we’ll tell you where the seconds are going.
Digital paralysis is the inability to execute, adapt or derive value from technology despite heavy investment. In a fab, it has recognizable signatures.
One lot move: the scheduler for the next lot, the special-work-request app for engineering instructions, SPC to confirm tool qualification, then the MES to execute. Four applications per move, thousands of moves per day, and the cognitive load and delay compound silently.
FDC flags abnormal equipment behavior but cannot tell the MES to stop the next lot. Metrology results land minutes late. Process windows at advanced nodes are narrower than the lag in the loop that protects them.
Process engineers know how to cut a qualification, tighten dispatch logic or remove a step. The change is trapped behind months of release cycle, so the fab’s rate of improvement becomes the software’s release schedule — and engineers build spreadsheets instead.
Product definitions, routings, equipment master data and process records live in several systems that were never synchronized. Decisions are made on whichever version loaded first. The discrepancy surfaces weeks later as a planning miss, a quality escape or a yield loss no one can explain.
A decade of customization layered into the MES model: hundreds of custom logic functions wired to one event, indexes added without a strategy, timeouts that silently stopped working. Each decision was defensible. The sum is a system that flips from “fine yesterday” to “slow today” after a statistics refresh.
Three people understand how the split/merge logic actually behaves. Two are eligible to retire. The documentation describes the system as it was designed, not as it runs. When they leave, every other risk on this list gets harder to diagnose.
Manufacturing organizations learned long ago that what gets measured gets improved. Equipment has availability, OEE, Cp/Cpk, MTBF and PM compliance, all trended, all with owners. Applications have availability and ticket counts, which say whether the software is on — not whether it is helping or hurting the fab. A system can hold 99.99% availability while adding two seconds to every transaction, fragmenting the data engineers decide on, and blocking the process improvements that would raise yield. From IT’s view it is healthy. From the fab’s view it is a constraint running every hour of every day.
Application Health is the discipline that closes that gap: measuring each application, and the estate as a whole, by whether it enables manufacturing to operate efficiently, adapt rapidly and hit its outcomes. Not once every three to five years in a consulting engagement, but continuously, the way equipment health is measured now.
Trended, owned, reviewed every shift.
Says whether the software is on. Not whether it helps the fab.
Equipment, automation, AI and people all depend on software. Applications are no longer IT assets. They are manufacturing assets.
Manage every system that participates in execution by its contribution to fab outcomes, not by service levels alone.
No fab waits three years to inspect a critical tool. Application health indicators belong on the same review as OEE and cycle time.
Every customization, business rule and interface encodes institutional knowledge. Capture it in the system, not in people.
Replace what constrains the fab or blocks the future, not what happens to be old.
AI makes decisions only as well as the systems, data and context beneath it. In a fragmented estate it accelerates bad decisions at machine speed.
The Axiarete platform ingests the artifacts that actually define your digital factory and builds a Technology Intelligence Graph: a living model of what every piece of software does, why it exists, what it depends on, how healthy it is and what it costs the fab.
Full visibility into every system, integration, dependency, health indicator, cost and risk — from the code up, not from the org chart down.
Rank every issue by fab impact — frequency × duration × proximity to a bottleneck tool or queue-time window — then remediate: performance, redundancy, technical health, capability.
Agentic operations across releases, enhancements, incidents and disaster recovery, with the graph kept current as the estate changes.
Parses and decompiles every artifact; builds and maintains the graph; scores each application on the six dimensions and the 300-point Technical Health Assessment; ranks findings by production impact; drafts remediations — rewritten queries, index designs, consolidated logic functions, configuration corrections; monitors continuously for regressions and new risk.
Validate every change against recorded production transactions; decide what ships; deploy to one site first; monitor for 72 hours; keep a tested rollback warm; and hand over the knowledge base, test suites and procedures so the capability stays with you.
Neither works without the other. We don’t pretend otherwise.
Start with the one that hurts most. The same graph powers all six, so every engagement compounds the next.
Forensic, code-level tuning of Camstar / Opcenter Execution estates: custom code, model artifacts, database, platform configuration and integration. Continuous issue detection, RCA and remediation once the baseline exists.
Outcome40–60% lower shop-floor latency; production configuration risks defused; zero functional regressions across two production tuning engagements.
How MES optimization works →Reconstruct the knowledge base for hundreds of applications directly from code and configuration; identify consolidation, retirement and modernization candidates with SME-validated evidence; build the business case.
Outcome$11M savings plan on a $40M baseline; 21% of the portfolio identified as reduction opportunity and validated by SMEs; months of manual analysis compressed to weeks.
Feature-level replaceability assessment against Siemens Camstar / Opcenter and SAP; auto-generated migration plans, test cases and requirements; risk discovery for version upgrades and post-M&A site consolidation.
Outcome90% accurate replaceability assessment validated by in-house experts.
The 300-point Technical Health Assessment across architecture, quality, performance, security and governance; code-level drill-down; business-impact modeling per issue; agentic remediation for the issues that matter.
Outcome50–80% reduction in architect and developer effort to understand and remediate issues; a standing foundation for enterprise technology risk governance.
End-to-end mapping of fab processes across the systems that execute them, with health, performance and cycle time per step; identification of friction, manual reconciliation and the toggle tax; optimization to reduce cycle time.
OutcomeProcess bottlenecks removed at the point where software, not equipment, is the constraint.
Unified risk discovery across source code, software supply chain and runtime for the applications that touch the fab; qualification by exploitability and production impact; agentic remediation.
Generic .NET and Oracle advice doesn’t fix an MES. Axiarete’s analysis targets MES constructs directly — grid display events, custom logic functions, business rule handlers, data objects, site feature flags, integration queues — with the failure modes known for each.
A standing capability, not a report. It keeps running after the engagement ends.
Both engagements were forensic: we decompiled the estate, measured every transaction, and rewrote what the evidence pointed to. Every rewrite was validated against recorded production traffic before it shipped.
The situation. Shop-floor grids and track-in / track-out had slowed unpredictably. Execution plans flipped overnight: fine yesterday, slow today.
| Finding | Before | After | Count |
|---|---|---|---|
| Setup-matrix lookups sorted entire tables to return one row | ROW_NUMBER() over a 25-level CASE sort after 28 joins; every row materialized | Indexed specificity score + FETCH FIRST 1 ROW ONLY; stops at the first row | 47 matrix queries re-engineered |
| Grid columns executed one query per displayed row | 16-join scrap-quantity query per row; a 100-row lot grid drove 400 history scans | Lookup folded into the grid query as a set-based join; one scan per render | 400 → 1 history scans per grid render |
| Predicate shapes that disabled every index | (col LIKE ? OR col IS NULL) stacked 20 deep; LIKE on Boolean and Integer columns | Exact-match / wildcard UNION ALL branches with typed equality; range scans restored | 365 index-killing predicates rewritten |
| Index estate and execution plans rebuilt on evidence | 125 redundant, 16 empty and 20-column-wide indexes; 20 on the hottest table alone | B-trees on 205 verified join paths; monitored drops; SQL Plan Baselines pinned | 125 redundant indexes retired |
The situation. Lot MoveOut, TrackIn / TrackOut and 2D Lot Start had slowed as a decade of customization layered into the model database. Thousands of metadata calls queued ahead of every commit.
| Finding | Before | After | Result |
|---|---|---|---|
| One MoveOut fired thousands of metadata functions before commit | 110 custom logic functions wired to one event: 2,696 calls; seven SkipPlan CLFs alone burned 424 | Early-exit consolidation; printing and trace codes moved to AfterCommit | 2,696 → 1,500 functions per MoveOut; latency down 40–50% |
| A sixth of the schema had no index; history queries scanned tables | 335 of 2,064 tables bare; 22 phantom indexes defined with zero columns | Composite B-trees on history mainline (ContainerName, TxnDateGMT, CDODefId) | 335 → 0 unindexed tables; history reads up to 80% faster |
| Every dispatch recomputed a static CDO hierarchy, recursively | 254 queries ran CONNECT BY / derived-CDO lookups over an unchanging tree | Hierarchy materialized, refreshed on deploy | 254 recursive lookups materialized; 1–4 s back per sequence |
| Dispatch grids fetched all 190 container columns to display 15 | 48 SELECT * queries; every default dispatch grid pulled the full row | CDO queries column-pruned to the 15 shown | 190 → 15 columns; payloads down ~90%; 1–5 s per dispatch list |
TABLE() context-switch calls re-engineeredReconstructed the knowledge base for a manufacturing portfolio from 12 million lines of code; ran the Technical Health Assessment on every application; distilled three rationalization scenarios.
Archaeological knowledge construction for hundreds of legacy manufacturing applications; feature-level replaceability assessment against Siemens Camstar and SAP; auto-generated migration plan, test cases and requirements.
No workshops before evidence. Analysis starts from your code on day one, and the executive review at the end of week eight decides whether to continue, change scope or stop — on results.
Analyze code, configuration, logs and incident records; produce an inventory of every customization. Add measurement: response time and database usage per transaction. Map the 8–10 transactions the fab depends on — move, split, hold, print, ship — and agree how incidents will be ranked by production impact.
Performance and KPI baseline by key transaction. Full inventory of customizations and every site-specific setting documented. First low-risk fixes discovered, prioritized and delivered — for example, correcting the setting mismatch that logs operators out mid-transaction.
Full roadmap prioritized by business impact and execution difficulty. Continue delivering — for example, timeout corrections so a slow step fails fast and releases its locks instead of blocking other users. SME reviews to validate and refine.
Validate every optimization and tuning opportunity. A twelve-month plan: optimizations, priority, action plans. Executive review: continue, change scope, or stop.
We can start with your top 2–3 of these.
And versus portfolio tools. CMDB, APM, TBM and EA tools are recordkeepers: they hold what you tell them, decay faster than teams can update them, and answer “what exists,” not “what to fix, retire or modernize, and why.” Axiarete reads the systems themselves and keeps the answer current.
Fab application estates encode process IP, routings, recipes and supplier relationships. We handle them under a signed NDA and a written data-handling agreement before any artifact moves, and we work from your stage environment with read-only database access wherever the work allows.
Why application intelligence has become the next competitive advantage in semiconductors. Introduces Application Health and its six dimensions, and the model for connecting software health to throughput, yield, cycle time and OEE.
Read the paper →How complexity is slowing decisions, eroding value and stalling AI. Four field cases from the authors’ careers in fab IT, what they have in common, and a 90-day path out.
Read the paper →Robots will close the labor gap and lean will keep grinding out process gains. The software that runs our factories is what stands between reshoring announcements and reshoring results.
Read the essay →Send us the custom code and the Designer model export — or the database workload reports and 90 days of logs — and within two weeks you will have a measured baseline of your key transactions, an inventory of every customization, and the first ranked list of what to fix. No workshops first. No slide deck about your industry. Evidence from your own estate.
Two hours a week from a project lead. Stage access only. An executive decision at week eight, on results.
We’ve received your request and will reply shortly to agree which inputs to start from.
Our deepest experience, and both production tuning engagements, are on Siemens Camstar / Opcenter Execution Semiconductor running on Oracle, with .NET / WCF customization. The Application Health discipline and the portfolio, modernization and technical-debt solutions apply across the estate regardless of MES vendor.
Both, in the right order. The platform first shows you which applications constrain the fab and which are redundant. You retire what is redundant, modernize what blocks the future, and optimize the core you are keeping — including the MES you will be running for years either way. The same evidence base carries into a Camstar V7 → Opcenter Execution upgrade when that is the right move.
It is a platform operated with you by forward-deployed engineers. The platform reads, models, scores, ranks, drafts and monitors; the engineers validate, ship, watch and hand over. The platform section above states exactly which is which.
Each customer operates in a dedicated AWS environment with AES-256 encryption, customer-managed keys and zero-trust access, with data residency defined by agreement. Customer code, models and logs are not used to train Axiarete or third-party models. See Security and data handling above.
First findings in week two. Quick wins — typically configuration and timeout corrections, index additions and the highest-volume query rewrites — are in production by week four. In our second tuning engagement, 20–30% of the total latency gain landed in the first two to four weeks.
A project lead for two hours a week, subject-matter experts for roughly a day in total across the eight weeks, and a sponsor for two hours. Everything else we take from the artifacts.