Smart manufacturing for semiconductors
Like many semiconductor companies, you've used lean initiatives to minimize waste and maximize productivity. However, today's rapidly evolving market demands more. For higher performance, you need to evolve from lean manufacturing to smart manufacturing.
Accelerate smart semiconductor manufacturing
Smart manufacturing digitalizes without disrupting lean gains. It integrates simulation, digital twins, collaboration, execution control, real-time analytics, optimizing high-yield, 'first-time-right' manufacturing. Closed-loop feedback enables learning, MES adjustments, AI adoption, and mitigating risk. This also boosts NPI yields, optimizes sustainability, and competes in real-time.
Why evolve lean to smart semiconductor manufacturing?
Remaining lean limits semiconductor companies' competitiveness, innovation, agility, and risk management. Evolve from lean to smart manufacturing for better decisions, faster NPIs and time to market, higher yields, and near zero defects.
2.5x Exceeds overall GDP growth
Investing in digital manufacturing solutions and technologies can help your company reduce costs, increase efficiency and boost your bottom line. (Forbes)
$1TRIL Expands globally 2030
Power innovation and reshape your industry with semiconductors. Embracing cutting-edge tech, talent and collaboration will be key to thriving in this dynamic landscape. (McKinsey)
3x Triples auto demand
Secure your chip supply chains and collaborate closely with semiconductor manufacturers to navigate this rapidly evolving ecosystem and deliver the next generation of smart solutions. (McKinsey)
Semiconductor manufacturing solutions
Transition to smart manufacturing with minimal disruption to your lean process. Explore our three digital transformation tracks. Solutions reduce risk, achieve first-time-right products, elevate yield, and rapidly grow your semiconductor business.
Leverage a virtual representation that simulates your entire manufacturing process nodes and fabrication lines to gain insights to optimize production and eliminate defects and re-spins for increased NPI yields and faster time to market. Continuously perform “what-if" analysis from current model updates. With virtual representation, you can:
- Leverage simulation models using Digital Twins concept to optimize and scale manufacturing performance.
- Minimize disruption to your current lean manufacturing process while enabling a smooth transition to a smart manufacturing environment.
- Reduce risk and achieve the right-first-time products.
Smart manufacturing enables adaptive and modular automation, which transforms automation systems from a hardware-centric approach to a modem software-centric approach for more efficient integration and extension of production systems.
- Adaptive production systems can rapidly adjust to changing markets, customize outputs, and reconfigure complex processes, while continuously improving quality and yield with minimal disruption.
With our energy-efficient automation engineering environment, and Industrial Operations X, we can optimize machine interconnection, flexible line automation and high-performance production.
- It includes Industrial Edge-based IT/OT convergence to unlock valuable data across product and production.
- AI-assisted factories with Automated Material Handling System (AMHS), and Robotics for fabs executing advanced nodes.
Highly automated Facility Monitoring and Control System (FMCS) ensures zero downtimes and maximizes availability in semiconductor production by providing real-time monitoring and control of facility operations, enhancing overall efficiency and reliability across the entire fab.
- Unified software + automation for FMCS excellence.
Smart and sustainable manufacturing begins with data. With manufacturing data collected in real-time you gain compelling advantages:
- Continuous learning and closed-loop quality improvement to execute advanced semiconductor fabrication runs.
- Harness real time manufacturing execution data to optimize simulation models for continuous improvement
- The ability to bridge IT and OT with real-time data flow, optimizing supply chain complexity and enhancing production agility. Additionally, you gain the power of Industrial AI to drive process optimization, improve yield, and accelerate decision-making.
- Predictive and prescriptive /preventive maintenance to minimize unplanned downtime and extend equipment lifespan, ensuring continuous, cost-effective production.
- Most importantly, scalable, future-ready automation for resilience, efficiency, and sustainability in both semiconductor fabs and sub-fabs.
Building on the platform of Lean techniques, the time has come for semiconductor manufacturers to expand into Smart solutions. Connecting every aspect of manufacturing and gathering real-time data will enable manufacturers to make intelligent decisions on market cycles, planning, production, capital investments and more. This will be necessary for succeeding in a new semiconductor world driven by chips going into almost every global industry.
Resources for semiconductor smart manufacturing
Discover valuable insights and solutions to empower your semiconductor manufacturing journey toward a digital enterprise. Learn from industry leaders as they share best practices and real-world examples of digital transformation in semiconductor production.
Smart solutions to optimize semiconductor manufacturing
IC manufacturing preparation
Elevate your semiconductor production with advanced planning, scheduling and dispatching, plant and process simulation to ensure manufacturing can execute seamlessly at every stage and all sites.
Manufacturing execution management
Optimize production with real-time visibility, with greater process flexibility and control to monitor operations, orchestrate resources, track products and ensure compliance.
Manufacturing process planning
Improve production by simulating, validating and streamlining processes to improve efficiency, reduce time to market and enhance collaboration.
Industrial IoT
Connect assets, collect real-time data and provide insights to optimize operations. Drive efficiency, improve quality and support new business models to transform manufacturing processes.
Application development platform
Empower experts to create custom apps with minimal coding. Extend legacy software and accelerate innovation. Leverage data, improve efficiency and enhance product development, manufacturing and supply chain processes.
Quality management
Integrate quality management across the product lifecycle to exceed customer expectations. Enhance product reliability, reduce costs, and ensure compliance, while protecting brand reputation and customer satisfaction.
Production Operation and Optimization
Advanced hardware and software enhance operational transparency and optimization. This enables predictive maintenance, boosts product reliability, reduces costs, and increases efficiency in semiconductor manufacturing.
Process Line Automation Engineering
Integrate complex machines into efficient semiconductor fabs. Enhance productivity and reliability through seamless integration with critical enterprise systems and advanced control, ensuring quality and cost-efficiency.
Industrial Systems Simulation
Flexible, modular systems meet customization demands. Boost efficiency and reliability with simulation and Digital Twins, optimizing delivery, accelerating time-to-market, and reducing semiconductor manufacturing costs.
Frequently asked questions
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Read
Blog Series | Sustainability in Semiconductors
Ebook | What does the smart manufacturing revolution mean for you?
White Paper | Security throughout the semiconductor lifecycle