Optimization of control software for automated wafer testing
Software Development
Hardware Connection
The Wafer Probe Controller software is specialized in-house software for controlling automated wafer testing in semiconductor production—modernized for Renesas Electronics with a focus on stability, user-friendliness, and interface integration. The application connects test and prober hardware in real time, replaces outdated GPIB communication with TCP/IP, and enables simulation testing without a production environment for the first time.
The Problem
We often encounter projects that have fallen out of maintenance – with challenges like these:
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Developer team no longer available
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Outdated technology stack
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Unstructured code with circular dependencies and no documentation
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No automated tests – changes only made directly in the production environment
Which Core Features Have Been Implemented?
Device Control / Hardware Integration
Data Analysis / Evaluation
Real-Time Monitoring
Notifications / Alarm System
Custom configurations
Versioning / Revision Security
Backup and Restore
Automated Processes
Our Expertise
Legacy Modernization with Structure and Foresight
We analyze and revise complex legacy applications – even without existing documentation.
Through targeted refactoring, technological updates, and clean architecture, we create stable, maintainable software solutions for long-term productive use.
Simulation & Testing without Production Risk
We enable safe development and QA through offline simulations that reproduce real process data.
This reduces risks, speeds up testing, and improves code quality – even with sensitive hardware integration.
Hardware Integration & Real-Time Communication
Whether GPIB, TCP/IP, or proprietary protocols: we seamlessly integrate machine control into existing systems.
Our focus is on real-time capability, low latency, and maximum reliability – even under production conditions.
Regulatory Awareness
Experience with requirements from semiconductor production (e.g., traceability, validation, documentation).
Feature Integration from External Systems
We adopt and integrate proven functionalities from third-party software into new or existing applications.
All without compromising usability or performance.
Agile Development with Direct Connection to Practice
Through close coordination with operational users, we create solutions that not only work technically but also excel in real-world operations – pragmatic and efficient.
What Makes Renesas' Project Special from a Technical Perspective
The modernized software is a native Windows application with direct hardware connection—developed for a highly specialized production environment in the semiconductor sector. Instead of modern cloud or web architecture, the focus here was on the technological renewal of a complex legacy system, including real-time communication, simulation, and migration.
Frontend
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Visual Component Library (VCL) + Windows API: Component-based development for classic Windows desktops; optimized for high performance and direct machine control
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C++ (Embarcadero RAD Studio): Modern IDE for maintaining and extending existing C++ applications with a focus on native GUI development and deep system integration
Backend
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Native C++: Direct low-level hardware access, real-time communication, and high execution speed
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Multithreading with clean synchronization mechanisms (mutexes): For stable and error-free parallel processes in real-time operation
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Automated unit tests (DUnit) & offline integration tests via log replay: Testability even without active hardware – safe, fast, and reproducible
Databases & Interfaces
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Oracle (ODBC): Stable, high-performance access to test and production data – compatible with the customer’s existing systems
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GPIB and TCP/IP sockets: Replacement of outdated USB-GPIB adapters with high-performance network communication – without production downtime
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Versioning & CI via Bitbucket: Improved traceability and collaborative further development
Key Features
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Simulation instead of production dependency: By replaying real test data, new features or bug fixes can be verified independently of hardware availability
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Integration of third-party software features: Previously external-only functionalities were fully integrated into the in-house solution
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Interfaces to legacy systems while modernizing the codebase: A technical bridge between past and future
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Our References
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