Robotic arm operating inside a modern cleanroom environment with advanced laboratory equipment and bright overhead lighting.

Analog Devices

Digital Twin of Semiconductor Manufacturing for ADI

Robotec.ai partnered with Analog Devices (ADI) to deliver a digital twin of its production bay. Using the RoSi platform, ADI can validate robotic workflows, human–robot interactions, and automation efficiency in a safe, virtual environment.

Goals

Create a digital twin of Analog Devices fab manufacturing area
Enable virtual commissioning of robotic systems to avoid costly mistakes
Validate automation scenarios including robots, humans, and process flow
Optimize throughput, efficiency, and safety in semiconductor production
Reduce costs and risks of physical prototyping

Benefits

High-fidelity 3D digital twin of the fab
Realistic simulation of robots and human agents
Full automation cycle: load–transport–unload–return
Reduced prototyping costs and risks
Improved safety and throughput in manufacturing

Case Study: ROBOTEC.AI + ANALOG DEVICES – DIGITAL TWIN FOR SEMICONDUCTOR MANUFACTURING

Customer: Analog Devices

Challenge

Analog Devices (ADI) needed a way to validate new automation workflows within a complex semiconductor production bay. Traditional testing on the physical site is costly, slow, and disruptive to operations. Key challenges included:

Building an accurate, interactive digital copy of the selected fab
Integrating mobile manipulators into the simulation
Modeling human–robot interactions safely, including emergency stop behavior
Simulating lot handling processes from loading to unloading
Providing outputs that help identify bottlenecks, idle times, and safety risks

Solution

Robotec.ai deployed its RoSi digital twin and simulation platform to deliver a customized simulation:

Virtual Site Model: Created a high-fidelity digital twin of the fab from scans, CAD models, and videos, including load ports, stairs, storage, and equipment.
Robots & Humans Simulation: Modeled mobile base with robotic arm and customized gripper, plus human agents in protective suits. Integrated realistic navigation, manipulation, and emergency-stop triggers.
Process Simulation: Implemented full load–transport–unload–return cycles with collision detection, physics, and dynamic object interaction (chairs, shelves, lot boxes).
Scenario Scripting: Developed real-world test scenarios for handling lots and interacting with workers.
Outputs & Integration: Connected to query and execute navigation goals and manipulator programs, enabling system integration and testing.

Results

The provided solution for ADI with a scalable framework for digital transformation in manufacturing:

Validated robotics workflows in a safe, virtual environment
Identified process bottlenecks before real-world implementation
Reduced costs by replacing expensive prototyping with simulation
Improved safety through human–robot interaction modeling

This case study demonstrated the value of digital twin technology in semiconductor manufacturing and set the foundation for broader deployment at ADI sites.