Case Study: LG Display– Quality Control System

CASE STUDY FOR MANUFACTURING

SPEEDIT

￭ Overview￭ Problems￭ Solutions￭ Results￭ Technical Details

AGENDA

In-Memory Database Solution

CASE STUDY FOR MANUFACTURING

+ Overview

AltibaseAltibase is provider of In-Memory database solutions for real-time access, analysis and distribution of high volumes of data in mission-critical environments.

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

SummaryAltibase enabled LG Display to possess an industry leading quality control system which resulted in increased revenue, profits, reputation, customer satisfaction and loyalty.

In-Memory Database Solution

+ ProblemsLG 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 DMBS’s perpetuated LG Display’s incapacity to monitor and react to these issues, lowering yield and leading to high scrap. Limited to tracking only lots, the automated system could not exploit the invaluable effects of pinpointing, per unit, imperfections1.

Numerous workstation reliance 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.

Quality control was relegated to 12-hour old data delivered in 10 minute intervals. LG Display found itself in a quandary. Increasing customer demand caused further

erosion in quality control, prompting unmanageable blows to profitability and reputation.

1) The ability to detect even the slightest flaw in a single plate or deposited layer is vital to the quality control process. In-Memory Database Solution

+ Solution LG Display implemented ALTIBASE HDB in-memory DBMS in

20081. ALTIBASE HDB captured defect data immediately and continuously2. LG Display’s quality control personnel could identify and remedy defects at the point and time of occurrence3.

In-Memory Database Solution

1) LG Display deployed ALTIBASE HDB hybrid technology (in-memory and on-disk) on a 20-core HP Superdome Server.

2) 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.

3) Prior to implementing ALTIBASE HDB, LG Display’s legacy system processed 21 million transactions per hour consuming 25%-45% CPU usage. With ALTIBASE HDB, 12 million transactions are processed per half hour with only 10%-20% CPU usage.

+ 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

defects1. LG Display implements practices to eliminate recurring breakage points. LG Display’s revenues, profits, reputation, customer satisfaction and loyalty

are bolstered by a superior product.

1) Manufacturing Process, human failure, environmental, or intertwined, cause and effect.

In-Memory Database Solution

+ Technical Details LG Display achieved outstanding results with their new Advanced LCD

Processing Control system by leveraging the key features of ALTIBASE HDB, specifically in the areas of high-performance, high availability and flexibility.

ALTIBASE HDB ALTIBASE HDBReplication

APCAhead Processing Control

In-Memory Database Solution

Active-ActiveMonitoring &Control

LG DisplayALTIBASE HDB

Active-Active ArchitectureAnd

Application Interfaces

+ Performance, Flexibility and High Availability: Before LG Display implemented ALTIBASE HDB, each manufacturing process was

managed by a dedicated conventional on-disk DBMS. LG Display desired to manage all manufacturing processes by using a single DBMS for more efficient administration of the 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 the conventional DBMS. LG Display’s performance requirements of 5800 TPS (transactions per second) for INSERT statements and 2100 records/hour for data migration were not met by the conventional 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 DBMS’s, for software updates and data integration tasks. The challenging administration tasks also resulted in numerous unplanned and planned system outages.

In-Memory Database Solution

+ Performance, Flexibility and High Availability: ALTIBASE HDB allowed LG Display to consolidate all existing DBMS’s into a single high

performing DBMS to monitor all manufacturing processes in real-time. Taking advantage of both the unique hybrid functionality and the built-in replication feature, LG Display implemented ALTIBASE HDB based on a 2-node, Active-Active architecture. In this architecture, both ALTIBASE HDB instances were configured in hybrid DBMS mode; in-memory DBMS + on-disk DBMS.

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

Active-Active HA architecture was realized using the built-in replication feature, allowing 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.

In-Memory Database Solution

In-Memory Database Solution

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