Semiconductors are critical components in the technology necessary to achieve carbon neutrality, from electric vehicles to renewable energy systems. These technologies have driven advancements in chip designs and placed higher volume demands on semiconductor manufacturers. Ironically, this need for more chips of higher complexity has increased the amount of energy required to produce semiconductors. This may seem daunting in the face of global sustainability goals, but there are steps semiconductor manufacturers can take to make production more efficient while improving quality and yield.
According to an article in Forbes, “Overall, the number of power semiconductors used in the global renewable energy market is expected to grow with a compound annual growth rate (CAGR) of 8% to 10% from now to 2027.” The semiconductor industry can use automated manufacturing solutions that integrate multiple factory systems to more sustainably meet these demands through increased efficiency and quality, which reduces energy use and waste as well as costly reruns.
Improved productivity
Manufacturers need to improve productivity to achieve greater efficiency in their fabs and automation software can help them do so in several ways. The software can be deployed to work with multiple production processes, such as lot tracking, scheduling, and distribution, and can integrate and process data. Automation software can help manage the supply chain to identify and reduce bottlenecks, reduce planning time and increase planner productivity, and improve on-time delivery and capacity usage. It also facilitates easier communication between different people in the factory to speed decision-making.
Additionally, semiconductor manufacturers achieve more efficient production by deploying AI and ML technologies with advanced and intelligent algorithms to solve quality, productivity and supply chain challenges.
Use simulation to maximize processes
Optimize use of resources
Sustainability goals are easier to reach when manufacturers make the best use of equipment. When equipment use isn’t optimized, energy is wasted, and manufacturers face costly repairs and replacement parts. Faulty equipment can also lead to defective products and production reruns.
A manufacturing scheduling system helps semiconductor manufacturers make the best use of their equipment and personnel resources. A quality factory scheduling solution can improve equipment efficiency and increase product quality and on-time delivery of products.
Additionally, automating maintenance management can help more efficiently manage the expensive assets of a fab while reducing the cost of repairs, parts and downtime waiting for equipment repair.
Predictive maintenance can make sure processes, equipment, and inspection systems are operating at peak efficiency, which reduces the risk of energy-intensive failures.
Hit quality goals and avoid reruns
Wasted material negatively impacts the manufacturer’s carbon footprint both in the energy used to manufacture replacement products and in their space in landfills. Fortunately, there are many automated manufacturing solutions that can help improve quality and reduce waste.
For example, statistical process control (SPC) tools can help manufacturers move from a detection-based quality control method to a prevention-based one. By identifying problems early, manufacturers can take actions to correct or prevent issues with process or quality before any product is impacted. These tools also provide valuable information to help them develop overall process improvement strategies.
Recipe management systems store recipes in a secure, central repository and reduce errors, improve efficiency, increase wafer output and provide traceability.
Strive for full-circle sustainability
Ultimately, semiconductors are vital to reducing the global carbon footprint and demand for them in these roles will likely grow. As the technology is deployed to bring innovative solutions to the world’s problem, manufacturers have many advanced automation options that can help them produce semiconductors more sustainably.
About Cindy McVey
Cindy is an essential writer for our SmartFactory Blog, focusing on feature stories that highlight automation experts and their contributions to helping semiconductor and pharmaceutical manufacturers stay ahead. Her engaging content explores how these experts navigate market dynamics, technology, and people to deploy innovative factory automation solutions. Cindy's insightful writing showcases the valuable insights and expertise these professionals bring to the semiconductor and pharmaceutical manufacturing industry.
