Embracing Innovation in Semiconductor Manufacturing

The semiconductor market landscape is evolving

Demand for semiconductors is rising. In the past, semiconductor industry growth was closely tied to consumer electronics like PCs and mobile phones. Now, digital transformation has accelerated across every industry, ushering in a new era of sustained semiconductor demand. The global semiconductor industry is projected to become a trillion-dollar industry by 2030.¹ Semiconductor manufacturers will need take steps now to meet this growing demand and stay ahead of the curve.

To take advantage of this growth, it’s important to look towards the future. Semiconductor fabrication plants (“fabs”) that re-evaluate operations and look for opportunities to innovate will be well-equipped to reap these benefits in the years to come. Making the right investments around four focus areas: maximizing yield, building resilience, empowering people and driving sustainability – will help semiconductor manufacturers meet demand and stand out from the competition.

¹The semiconductor decade: A trillion-dollar industry." McKinsey, 2022.

1. Maximize yield with smart manufacturing solutions

Maximizing yield is essential to meeting semiconductor demand. As demand for semiconductors increases, keeping up with rising KPI targets will only become more and more challenging. Additionally, aging hardware could prevent fabs from successfully meeting demand and maintaining high uptimes in the years to come. Considering new ways to maximize yield will set fabs up for success now and in the future.

Semiconductor manufacturers can maximize yield by investing in smart manufacturing technologies that maximize uptime, efficiency and quality. For some fabs, this may look like automating material handling to maximize tooling uptime. Others may implement smart scheduling systems powered by AI and ML to optimize material flows or implement quality management systems coupled with predictive analytics to help catch production anomalies. Preconfigured tools and libraries can also help accelerate time to market. In addition to maximizing yield, it’s also important to consider ways to increase operational resilience.

2. Build resilience across operations

Developing the resilience to successfully overcome future challenges is critical to the success of every semiconductor manufacturer. While it’s impossible to know what the future holds, managing risk is key to building this operational resilience. Fabs today face a variety of risks, from mounting cybersecurity concerns and complex supply chain challenges to employee safety and project risks. The right technologies can help fabs stay ahead of risk without impacting productivity.

To manage risk, fabs need the visibility to identify potential risks and the tools to successfully mitigate them. For semiconductor manufacturers looking to strengthen cybersecurity, this could look like implementing smart systems with role-based permissions to secure operations and protect sensitive IP. Those seeking to minimize project risk may implement a centralized supply chain management hub to increase operational visibility. Another area of risk that semiconductor manufacturers should consider is the growing talent shortage.

3. Empower people to build the workforce of today, and tomorrow

The widening skills gap has made growing and upskilling the semiconductor workforce more important than ever.  And as the semiconductor industry shifts to meet more complex demand, this skills gap will only continue to expand. By 2030, the semiconductor industry is expected to require more than one million additional skilled workers to meet demand.² Semiconductor manufacturers will need to innovate to equip the workforce of today and prepare the workforce of tomorrow.

To build up the semiconductor workforce, fabs need the right technology to both enable existing workers to excel in their positions and inspire the next generation. For some fabs, this may look like implementing AR/VR solutions to enhance operator training and reduce maintenance time. Automation and digital twin solutions can further optimize processes and free up workers to focus on higher value tasks. Leading companies are also increasingly creating academic consortiums to prepare students for the semiconductor industry of the future.

² “THE GLOBAL SEMICONDUCTOR TALENT SHORTAGE.” DELOITTE, 2022.

4. Drive sustainability by targeting inefficiencies

Enabling sustainable semiconductor manufacturing is more than just a social responsibility – it’s now mission-critical. As semiconductor fabs expand to meet current and future demand, so do their environmental footprints. Meeting sustainability goals while continuing to make production targets will continue to be an important area of focus for semiconductor manufacturers in the years to come.

Sustainable semiconductor manufacturing requires innovative technology to pinpoint opportunities for improvement. By leveraging data from new and existing automation technologies with advanced AI and ML solutions, fab operators can construct digital twins to drive efficiencies across energy, water and waste. Digital twins can also be used to implement innovative technologies such as water-cooled chiller systems to reduce water and energy consumption. By working to make operations more sustainable, fabs will be well-positioned to lower costs and meet regulatory requirements now and in the future.

Innovate with Rockwell Automation

At Rockwell Automation, we’re dedicated to helping our customers embrace innovation to meet the semiconductor demand of today and the future by maximizing yield, building resilience, empowering people and driving sustainability. We take a data-first view to innovation, supporting our customers along their data journeys with our vast partner ecosystem, solutions, services and consulting expertise. Our experts can help you reach your goals at scale, so that you can be ready, no matter what tomorrow brings.