Sponsored by AvantesReviewed by Maria OsipovaMay 27 2024
Rapid technological advancements are significantly transforming conventional manufacturing. Contemporary data science is leading the emergence of ‘smart manufacturing’, inspiring fundamental changes in how processes are developed, monitored, and assessed.1 Smart manufacturing aims to boost productivity, sustainability, and economic performance by seamlessly integrating all operational systems within industrial enterprises.
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This article investigates the role of spectroscopy in revolutionizing smart manufacturing, showcasing how it assists in fostering improved product consistency and quality, as well as proactive process optimization.
In-Line Process Analytics
In smart manufacturing, timely and accurate data flow is critical. Manufacturers seek to monitor every step in their process to ensure optimal results. However, significant challenges include preventing defects, gaining precise control over manufacturing parameters, and maintaining adaptability in dynamic environments.
In-line process analytics are crucial to addressing these challenges.2 This approach allows for direct measurement of the main parameters in each process in real-time, which is unique from traditional online analysis methods that use sampling loops. With continuous, real-time data, in-line process analytics enable manufacturers to quickly adjust parameters, optimizing product quality, yield, and throughput.
Spectroscopy: Revolutionizing Manufacturing
Over the past 20 years, industries ranging from pharmaceuticals to polymers and semiconductors have shown an increase in embracing the development of advanced in-line monitoring techniques for process analysis. Spectroscopy stands out in the world of advanced sensing technologies driving in-line process analytics.
Spectroscopy is a method for analyzing the interaction between matter and electromagnetic radiation. It is crucial in smart manufacturing, particularly when optimizing in-line processes for improved overall operational efficiency and product quality.
In combination with machine learning, spectrometers can help predict and prevent defects. By using spectroscopic techniques, manufacturers can gain precise control over processes and ensure optimal product quality and consistency.
The pharmaceutical industry is an example of where the implementation of spectroscopic techniques is becoming essential for quality control. Techniques like Raman spectroscopy make it possible to set up in-line monitoring for therapeutic manufacturing processes, like monoclonal antibodies.3 The measured spectra can subsequently be utilized to identify the concentration and discover other information, such as confirming contaminants or active ingredients.
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Other examples include automated process optimization and control.4 For this, a spectrometer detects the chemical signature of the desired product. Variations in reaction conditions, such as pressure or temperature, can reveal the yield of particular product species. Feedback loops can be established as required. Employing optimization algorithms allows the identification of a highly effective combination of reaction parameters for optimal production outcomes.
The data collected is information-rich with spectroscopic techniques regarding concentrations, sample purities, etc., meaning some parameters can be compared for sample-to-sample consistency and quality control.
Avantes’ Spectrometer Solutions
Avantes provides an array of advanced high-speed spectrometers ideal for in-line process optimization, including the next-generation NEXOS5 and VARIUS6 devices. These spectrometers have superior optical performance and customizable characteristics, facilitating high-precision monitoring and control of critical manufacturing parameters with real-time data provision.
The NEXOS Spectrometer is lightweight and compact, integrating various devices and sensors into smart manufacturing systems. Users can choose from multiple configurations of slits and gratings to align with particular requirements, as well as with different communication protocols like USB2, RS232, direct interfacing, and SPI. This flexibility enables manufacturers to adjust quickly based on real-time spectroscopic data and meet various product specifications.
Varius also offers unmatched flexibility, with a novel magnetic connector cover that makes slit replacement easier and enhances performance with a patent-pending improvement to the optical bench. Available in standard compact and industrial (OEM) variations, Varius suits laboratory settings and industrial applications.
Compact spectrometers integrate seamlessly with various sensors and devices in smart manufacturing systems, making them more functional and versatile. The spectrometer can compile comprehensive data from pressure sensors, temperature sensors, flow meters, and other monitoring devices often used in manufacturing for better precision and control. Built for seamless integration into smart manufacturing systems, Avantes’ compact spectrometers provide a customized solution for in-line process optimization.
Case Study: Plasma Etching in the Electronics Industry
To illustrate the practical applications of Avantes’ spectrometer solutions, an electronics industry case study showcases their effectiveness.
Plasma processing is crucial in manufacturing integrated circuits (ICs) and microelectronics. Engineers utilize plasma etching to create intricate features and patterns on semiconductor layers. However, monitoring this process in real-time is critical to ensuring precise control of the material removal, minimizing defects, and optimizing final product quality.
An optical emission spectrometer like Avantes’ AvaSpec-ULS4096CL-EVO (the predecessor of Nexos and Varius) allowed manufacturers to monitor the plasma etching and automated layer deposition processes in real-time.7 The researchers had precise control over material removal from the layers on the ICs, letting them know precisely when all undesired material had been removed (the end point). This resulted in a tightly controlled process that generated high-quality products.
By integrating in-line spectrometers into the study, the researchers significantly improved the plasma processing method's precision and efficiency, enhancing overall quality assurance and manufacturing precision.
Conclusion
In-line spectroscopic tools are crucial in optimizing processes in smart manufacturing operations, enhancing efficiency and product quality while also minimizing waste and defects. Avantes’ compact spectrometers lead this technological revolution, so manufacturers can be confident in navigating modern production’s complexities, equipped with the tools needed for success.
References and Further Reading
- The Smart Manufacturing Institute. What Is Smart Manufacturing? - CESMII
- Tschudi, J et al. Inline Spectroscopy: From Concept to Function. Applied Spectroscopy 2018, Vol. 72(9) 1298–1309.
- Wang, J., Chen, J., Studts, J., & Wang, G. (2023). Automated calibration and in-line measurement of product quality during therapeutic monoclonal antibody purification using Raman spectroscopy. Biotechnology and Bioengineering, 120(11), 3288–3298. https://doi.org/10.1002/bit.28514
- Bédard, A., Adamo, A., Aroh, K. C., Russell, M. G., Bedermann, A. A., Torosian, J., … Jamison, T. F. (2018). Reconfigurable system for automated optimization of diverse chemical reactions. Science, 361, 1220–1225. https://doi.org/
- Avantes. AvaSpec-NEXOS™ Meet the next-generation compact backbone spectrometer. https://www.avantes.com/products/spectrometers/compactline/avaspec-nexos
- Avantes. VARIUS™ Spectrometer. https://www.avantes.com/products/spectrometers/starline/avaspec-varius
- Kane, J. Spectroscopy Applications for Plasma Monitoring. PhotonicsViews Volume 16, Issue 3 p. 64-67 (2019).
This information has been sourced, reviewed and adapted from materials provided by Avantes BV.
For more information on this source, please visit Avantes BV.