Packaging Sentinel
The Economic Guardrail for Advanced Packaging
"Continuous, low-cost operational reasoning with Gemini 3.5 Flash: Compressing the post-alert investigation window to protect multi-million dollar yields."
Today, factories don't lack data.
But when an alert fires, engineers spend hours manually querying scattered databases to isolate the root cause.
- Scattered Data Silos: Lot genealogies, sensor traces, strip maps, and X-ray/SAM scans are stored in separate, isolated databases.
- Manual Cross-Examination: Yield engineers spend hours querying databases, matching sensor spikes, and diagnosing failure signatures.
- Active Line Exposure: While the investigation drags on, the factory continues running, risking millions of dollars in packaging scrap.
Why the drift window matters
In advanced packaging (CoWoS/SiP), yield loss scraps highly valuable products. We are no longer just scrapping plastic, but world-class silicon.
- High-Value Packaging: Packaging combines pre-tested, high-cost silicon dies. A single packaging defect destroys the whole $40,000 package.
- Severe Capacity Waste: Packaging capacity is extremely tight. Scrapping parts wastes scarce machine hours and delays massive shipments.
- Yield Economics: Compressing the drift-to-containment window protects expensive multi-die substrates from compounding scrap costs.
Formula: Wafers/mo × 12 × Dies/Wafer × 1% Loss × Value/Die
Real-Time Anomaly Screen & Continuous Reasoning
A data flow architecture where continuous background anomaly screens trigger a Test-Drift Watcher and spawn long-running reasoning agents.
- Continuous Data Flow Screen: High-speed streaming SPC (CUSUM) and Dynamic Time Warping (DTW) algorithms continuously screen raw physical sensor telemetry and electrical logs in the background.
- Lightweight Test-Drift Watcher: The moment a statistical threshold is crossed, a lightweight trigger opens the incident state and isolates initial suspect lot boundaries.
- Long-Running Agent Layer: Spawns specialized multi-agent sub-track investigators on top of the watcher to query databases, perform commonality calculations, analyze visual voiding/delamination, and challenge hypotheses.
- Defensible Production Guards: Ensures zero autonomous physical holds or shutdowns; drafts cited containment recommendations for direct engineer review.
Layer 1: Real-Time Anomaly Screen (Continuous)
High-speed SPC (CUSUM) and Dynamic Time Warping (DTW) screen raw FDC sensor telemetry & electrical bin streams.
Layer 2: Test-Drift Watcher Trigger
A statistical threshold breach instantly fires. Registers the incident and identifies the initial lot drift boundaries.
Layer 3: Long-Running Swarm Agents (On Top)
Launches specialized investigators in parallel (Genealogy, X-Ray Vision, Reflow Trace, Falsification) to cross-correlate evidence.
Layer 4: Defensible Handoff Packet
Incident Commander consolidates all findings, cites direct source logs, and drafts human-approval containment actions.
Why Gemini 3.5 Flash is the key unlock
Operational intelligence was economically impossible with older frontier models. Gemini 3.5 Flash makes continuous background agent loops commercially viable.
- Continuous Operational Viability: Low latency and massive context sizes at near-zero operating cost make background agent streams feasible.
- Highly Capable Tool-Calling: Reliably translates high-level coordinates into discrete API calls to query assembly travelers and CSV logs.
- Multimodal Speed: Instantly processes physical package strip maps, acoustic imagery scans, and telemetry charts in parallel.
An agent swarm of narrow packaging specialists.
A single general-purpose prompt fails on messy factory evidence. We coordinate specialized roles, each with a narrow scope.
- Coordinated Intelligence: Individual specialists execute tasks and return structured outputs to an Incident Commander.
- Adversarial Verification: The Falsification Agent attempts to disprove hypotheses, ensuring extreme confidence.
- Falsification Integrity: Proactively queries disproof criteria to prevent confirmation bias and guarantee high-fidelity root cause claims.
Tested against concrete industrial incident replays.
Our fault-injected digital twin simulates realistic packaging incidents with precise manufacturing artifact records:
- Realistic Industry Replays: Standardized data formats (ATDF final test, E142 package layouts, CSV telemetry).
- Actionable Containment Plans: Concrete evidence files, statistical checks, and disproof guidelines generated.
- Automated Hold-List Mapping: Swiftly bounds downstream lots affected by equipment excursions to halt line propagation.
Telemetry anomaly identified in REFLOW_07_ZONE_C. Solder voids mapped to Strip corner pins.
No blind AI decisions. Just direct, actionable evidence.
The product concept is not "AI makes line decisions on its own." That is not credible in high-precision semiconductor environments.
- The Wedge: Compress the investigation window to produce a beautifully structured, cited, and scoreable engineer-review packet.
- The Evaluation: We take historical, synthetic, or anonymized packaging incident logs and replay them through Packaging Sentinel.
- The Goal: Prove that managed agents can pinpoint affected lots, list correct containment files, and establish disproof checks faster than manual silos.
Evaluation Objective