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DCSF19 Transforming a 15+ Year Old Semiconductor Manufacturing Environment

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Jeanie Schwenk, Jireh Semiconductor

Jireh Semiconductor bought the Hillsboro fab and its contents including the manufacturing tools, servers, and software running the fab. The previous company had been winding down for years so server and software upgrades had not been on the radar for some time. In 2011 Jireh became the proud owner of the building, the tools, and its legacy software running on servers that weren’t even made any more.

That's when I started my adventure with Jireh in September 2016 with a charter to modernize the applications running the manufacturing facility process and move them into VMs with no impact to manufacturing. That led me down a path of exploration and questions. “What’s the goal?”

The goal wasn't to move to VMs. It was to become independent of the aging PA-RISC architecture, bring forward the ~230 java 1.4.2 applications (10-15 years old), scale to allow increased the load on the software and hardware in order to ramp the factory output to numbers never seen previously. And do it without manufacturing downtime.

The solution included a transition from waterfall and silo development to agile scrum. Rather than simply migrating to VMs, it became obvious the lynch pin for a successful software transition with the required uptime, flexibility, and scalability was Docker Enterprise.

Join me for this session where I'll talk about my journey modernizing 15+ year old applications and infrastructure at Jireh.

Publié dans : Technologie
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DCSF19 Transforming a 15+ Year Old Semiconductor Manufacturing Environment

  1. 1. Scrum Master, Software Engineer Jireh Semiconductor Jeanie M Schwenk
  2. 2. • 20+ years experience in software industry • BS in Computer Science • MS in Computer Science • Masters Certificate in Software Engineering • PMP (PMI.org) • PSM (scrum.org) • PSPO (scrum.org) Professional Background
  3. 3. Personal
  4. 4. Jireh Semiconductor – AOS Family Bringing manufacturing back to the US profitably
  5. 5. Power IC, TVS IGBT High Voltage Power MOSFET (>400V) Middle Voltage Power MOSFET (40V~ 400V) Low Voltage Power MOSFET (< 40V)
  6. 6. History Timeline Jireh Former company ended capital investment AOS foundry AOS purchases fab + contents Adapt designs Purchase and install tools Joined the team Improve software systems and increase volume 2008 2011 2013-2016 2015 Fall 2017
  7. 7. The IT - Automation Team
  8. 8. Joining the Jireh Team What’s your goal? • Coach the team transform to Agile Scrum • Modernize the ~230+ applications • Become independent of the PA-RISC servers • Ramp factory output to numbers never seen before • No downtime • No impact to manufacturing
  9. 9. Nobody Plans to be in This Position © Disney/Lucasfilm
  10. 10. The Plan to Meet the Goal • Transition from Waterfall to Agile Scrum • Transition from Silos to Teams • Modernize the Hardware • Modernize the OS • Modernize the applications • No downtime/impact to manufacturing while doing it
  11. 11. Where to Start 1. Team assessment / Teach agile and scrum 2. System communication. How does this system work? 3. Build, run, and understand java applications 4. Look into options for virtualization of applications Fit in our manufacturing environment Maturity of the product High availability Support Cost 5. Look into Legacy Operating System
  12. 12. People and Processes People resist We like what is familiar We don’t like change Agile mindset “It's a competitive world out there. If you aren't looking to improve how you do things, and you're not willing to change, you'll become irrelevant.”
  13. 13. We have to test the MES manually. We’re too small We can’t do agile or scrum, it just won’t fit here The Team’s Response We’re too interrupt driven. We’re too specialized. We can’t add unit testing – it’s too big. Our PA-RISC servers can’t be upgraded. No forward path We can’t virtualize it. It’s tied to the hardware.
  14. 14. Legacy Servers MES - WorkStream COMETS Remotes Database 9.4 WorkStream + DB HP-UX Server Equipment Controllers and Drivers HP-UX Server DBS Applications 1 of each HP-UX Server DBS Applications 1 of each HP-UX Server DBS Applications 1 of each HP-UX Server Equipment Controllers and Drivers HP-UX Server Equipment Controllers and Drivers HP-UX Server Equipment Controllers and Drivers HP-UX Server WSMsrv HP-UX Server Shared memory
  15. 15. Getting Legacy Monolith to Containers • Know your system • Set a clear goal for short-term and long-term - pull apart and isolate each component - be able to migrate or replace any single piece without impact to a running factory • Create a transition plan • Risk analysis (deal breakers) • Proof of concept to obtain buy-in
  16. 16. Systems and Communication WSMsrv (20) Job ontroler Job Setup (3) Fab View (3) GUI (n) Job Controller (3) CMMSG VFEI VFEI Equipment Controller Driver Equipment SECS II VFEI 3 servers 9 applications 4 servers ~240 EQCs ~240 drivers Shared memory MES - WorkStream COMETS Remotes Database 9.4 WorkStream + DB HP-UX Server
  17. 17. The Plan for Enterprise buy-in 1. Docker Engine (CE) on my PC 2. Obtain VM running Ubuntu 3. Get main three applications to run in the VM 4. Install Docker Engine (CE) on the VM 5. Get three main applications to run in a container (test VM) Docker Engine (CE) on PC A Docker Engine (CE) on VM B Docker Enterprise on 10 VMs C
  18. 18. Eliminate deal breakers • Message bus across versions and systems – Get message bus to run on VM Get message bus to run in container • Send/receive messages via command line • Start applications from command line • Change operating system • Migrate java version as far forward as possible • Separate applications • Accessible application logs
  19. 19. Transition to Docker Container • Create Docker image in CE – identical to VM • Run in container in Docker Engine (CE) • Get buy in for Docker Enterprise • Determine minimal set for container Library dependencies $PATH and environment vars Start application from the command line • Move to smaller footprint OS - Debian • Run in Production swarm in Docker Enterprise***
  20. 20. Moments of Failure • Running 1.4.2 under different OS • Finding the right OS • Finding the right jdk • Can’t run from command line • Non-existent runtime flags • Library dependencies Libraries not available Incompatible library errors
  21. 21. Moments of Failure • Environment variables • Startup errors in the logfile • Wrong files in repo • Files in production not in repo • Unmet dependencies/broken pkgs • “Undefined” dependencies • ELFCLASS32/64 architecture mismatch errors
  22. 22. Moments of Failure • Test send/recv program not just command line Big endian, little endian errors • Unable to install msg bus in container as part of Dockerfile - learn expect • Disabled stack guard errors (execstack) • File to big to get out of repo • Core dumps (ipv6 issue)
  23. 23. Example Breadcrumb # A fatal error has been detected by the Java Runtime Environment: # Internal Error (os_linux_x86.cpp:291), pid=7026, tid=0xf66a1b40 # fatal error: An irrecoverable SI_KERNEL SIGSEGV has occurred due to unstable signal handling in this distribution. # # JRE version: Java(TM) SE Runtime Environment (8.0_181-b13) (build 1.8.0_181-b13) # Java VM: Java HotSpot(TM) Server VM (25.181-b13 mixed mode linux-x86 ) # # An error report file with more information is saved as: … hs_err_pid7026.log # # The crash happened outside the Java Virtual Machine in native code. Aborted (core dumped) … An unexpected exception has been detected in native code outside the VM. Unexpected Signal : 11 occurred at PC=0xF768C3A1 Function=inet_pton+0x161 Library=/lib32/libc.so.6
  24. 24. Snippet of CE Dockerfile
  25. 25. Snippet of CE Dockerfile
  26. 26. Shared memory Legacy Servers Where we started MES - WorkStream COMETS Remotes Equipment Controllers and Drivers HP-UX Server DBS Applications 1 of each HP-UX Server DBS Applications 1 of each HP-UX Server DBS Applications 1 of each HP-UX Server Equipment Controllers and Drivers HP-UX Server Equipment Controllers and Drivers HP-UX Server Equipment Controllers and Drivers HP-UX Server Database 9.4 WSMsrv HP-UX Server WorkStream + DB HP-UX Server
  27. 27. Virtualization: Where we’re going HP-UX Server WorkStream COMETS Remotes Database 12.10 VM - RedHat Equipment Controllers DBS Applications Equipment Controllers Equipment Controllers Drivers WSMsrv HP-UX Server DBS Applications DBS Applications Equipment Controllers Equipment Controllers Drivers
  28. 28. Future - MES Server 3 options for future • Refurbished rp**** servers • Refurbished rx**** servers • HP9000 PA-RISC emulation We’ll be seeing a demo from them in May
  29. 29. Architecture DOCKER ENTERPRISE Management Plane CE Node Nginx LB for UCP CE Node Nginx LB for DTR Registry Node Manager Node Manager Node Manager Node DTR Node DTR Node DTR Node Worker Node Worker Node Worker Node Worker
  30. 30. Is Containerization For You? • Maybe a container isn’t your first stop • What are your risks? • What’s your goal? • Does the legacy application have a future? • Do you have a plan B? • Time/resources to devote? • Anyone know Docker • Start new services? • New development in containers and keep the legacy around until replacement is ready? • Do you know your application? • How will you manage the moments of failures?
  31. 31. Thank you! Rate & Share Rate this session in the DockerCon App

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