Project Name: Semiconductor Facility SCADA Server & PLC Upgrade

Facility:
Skyworks Solutions - Semiconductor Manufacturing
Newbury Park, California

Scope:
Control Engineering, Inc. was selected to modernize the facility's legacy SCADA server and PLC infrastructure to improve reliability, cybersecurity compliance, and long-term supportability within an active semiconductor production environment.

The project included:

• Replacement of aging SCADA server hardware with new industrial-grade server infrastructure
• Migration to updated SCADA software platform
• Upgrade of legacy PLC processors to current-generation controllers
• Standardization to Ethernet/IP network architecture
• Database configuration and historian implementation
• Recreation and modernization of HMI graphics
• I/O validation and field verification
• Coordination with internal IT for network security and remote access compliance
• Commissioning, testing, and documentation

All work was performed while maintaining continuous production, requiring careful sequencing, validation, and rollback planning.

System:
The upgraded architecture centralized plant data collection and improved system scalability across production areas.
Core system components include:

• Modernized SCADA server platform
• Updated PLC controllers
• Ethernet/IP communications backbone
• Centralized SQL-based historian
• Alarm management and trending tools
• Role-based security access
• IT-compliant network segmentation

The system was engineered for long-term maintainability, improved redundancy strategy, and expansion to support future production lines and process equipment.

Benefit:
The modernization eliminated unsupported hardware and software dependencies while significantly improving system reliability.
Key outcomes include:

• Reduced downtime risk
• Improved data visibility and traceability
• Enhanced cybersecurity posture
• Standardized controls architecture
• Scalable infrastructure for future expansion
• Improved long-term serviceability

This project demonstrates CEI's ability to execute high-precision SCADA and PLC upgrades within regulated semiconductor manufacturing environments while maintaining operational continuity and strict IT compliance.