GOOGLE HACKATHON ENTRY // OSAT YIELD ASSURANCE
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."
The challenge isn't raising the alert. It is the chaos after.
Existing systems (MES, SPC, inspection, test analytics) raise flags instantly. But the engineering investigation that follows is slow, manual, and highly fragmented.
- 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 Math: Play with the calculator to see the staggering cost of a single percentage point of yield loss over a year.
Formula: Wafers/mo × 12 × Dies/Wafer × 1% Loss × Value/Die
Continuous reasoning above the factory floor.
Package Sentinel does not replace existing SPC, MES, or inspection systems. It sits on top of them, acting as an instant digital detective.
- Instant Investigation Trigger: The moment a test-drift alert fires, Package Sentinel pulls genealogies and traces automatically.
- Multimodal Inspection Layer: Inspects images (X-ray, SAM), parses raw telemetry (reflow traces, dispense weights), and charts spatial fail maps.
- Compressed Response Window: Delivers a highly structured, cited engineer-review packet with affected lots, evidence, and disproof metrics in minutes.
1. Watch Drift
Continually scans streams and fires when SPC thresholds are crossed.
2. Investigate
Spawns specialists to compile reflow logs, wafer layouts, and test records.
3. Verify Claims
Falsification agent challenges evidence to ensure hypotheses are bulletproof.
4. Contain
Provides the engineer a complete cited hold list and actionable tasks.
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.
Gemini 3.5 Flash offers the perfect sweet-spot: capable multi-step reasoning with near-zero operating costs.
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.
- Swarm Sandbox: Click the agent buttons on the right to see active specialists and view their specific factory operational runbooks.
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.
- Interactive Sandbox: Select Case A, B, or C to inspect the fault-injected failure canvas preview.
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 Package 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