Real Time Flaw Detection – LG Display

LG Display switched from Oracle to Altibase for its real time flaw detection systems, resulting in 50% reduction in product loss and CPU resources.

Use Case: Real Time Flaw Detection and Management

Current Customers: LG DISPLAY

Industry: Manufacturing

Who

LG Display is the world’s largest LCD panel producer.

Problem

LG Display suffered from inadequate quality control. Its inability to track defects and change requirements in real time was at the core. Data stored on multiple DMBSs perpetuated LG Display’s incapacity to monitor and react to the issues of lower yield and leading to high scrap. Limited to tracking only lots, the automated system could not exploit the invaluable effects of pinpointing per unit.[1]

  • Reliance of numerous workstations on multiple databases led to substantial performance degradation, triggering uncontainable defects.
  • Vital quality control protocols went unanswered. Specifically, composition ratios of active substrates and color filters were unidentified until it was too late.
  • The delivery time of quality control data was relegated from 10 minutes to 12 hours.
  • LG Display found itself in a quandary. Growing customer demand caused further erosion in quality control, prompting unmanageable damages to quality reputation and profitability.

Solution

LG Display adopted Altibase in 2008.[2] Altibase with hybrid architecture captured defect data immediately and continuously.[3] The quality control personnel could identify and remedy defects at the point and time of occurrence.[4]

Results

  • LG Display possesses an industry leading quality control system.
  • Precise product manufacturing processes are wed with exacting defect detection.
  • Personnel isolate problems instantly and act on accurate data, reforming communication.
  • LG Display relies on stringent data streams, quickly identifying root causes of defects.[5]
  • LG Display implements practices to eliminate recurring breakage points.
  • LG Display’s revenues, profits, reputation and customer satisfaction and loyalty are bolstered by superior products.

Technical Details – Real Time Flaw Detection

LG Display achieved outstanding results with its new advanced LCD processing control system by leveraging key features of Altibase’s hybrid architecture, specifically in the areas of high performance, HA and storage flexibility.

High Performance, Storage Flexibility and HA

Before LG Display implemented Altibase, each manufacturing process was managed by a dedicated, legacy on-disk DBMS. LG Display desired to manage all manufacturing processes by using a single DBMS for more efficient administration of monitoring systems and to have an integrated view of all manufacturing processes. However, the idea of a centralized DBMS system was not possible due to poor performance of its legacy DBMS. LG Display’s performance requirements of 5,800 TPS for INSERT statements and 2,100 records/hour for data migration were not met by its legacy DBMS.

Besides the performance issues, the need to maintain a dedicated DBMS for each manufacturing process created major challenges in the areas of application development and maintenance, as well as database administration and tuning. The developers had to deal with an extremely complex application infrastructure. The database administrators had a difficult job of administering a large number of DBMSs for software updates and data integration tasks. The challenging administration tasks also resulted in numerous unplanned and planned system outages.

Altibase allowed LG Display to consolidate all existing DBMSs into a single, high performing DBMS to monitor all manufacturing processes in real time. Taking advantage of both the unique hybrid architecture and the built-in replication feature, LG Display implemented Altibase based on a 2-node, active-active architecture.

This architecture was the perfect fit for eliminating performance, administration and reliability issues of LG Display’s legacy systems. Altibase’s in-memory feature delivered extreme speed for real time monitoring of all manufacturing processes by delivering 50,000 TPS performance for INSERT statements. Altibase’s on-disk feature was used as the repository for 12-hour and older manufacturing process data. Migrating data from memory tables to disk tables was a simple task attributable to Altibase’s unique MOVE SQL statement. With the MOVE statement, LG Display was able to migrate data from memory tables to disk tables at a 10,000 TPS performance.

Active-active HA architecture was realized using the built-in replication feature. LG Display utilized Altibase’s synchronous replication in a shared-nothing configuration with a zero downtime topology. With the new architecture, day-to-day tasks for both application developers and database administrators were greatly simplified.


[1] The ability to detect even the slightest flaw in a single plate or deposited layer is vital to the quality control process.

[2] LG Display deployed Altibase with hybrid usage on a 20-core HP Superdome Server.

[3] LG Display received real time defect data on a micro level per product. Data was further broken down by station, time of process deviation and composition layer.

[4] Prior to adopting Altibase, LG Display’s legacy system processed 21 million transactions per hour consuming 25% – 45% CPU usage. With Altibase, 21 million transactions are processed per half hour with only 10% – 20% CPU usage.

[5] Manufacturing process, human failure, environmental or intertwined cause and effect

Downloading is believing.