1. Energy efficiency: a key to lowering costs
Energy costs are a significant factor in the manufacture of semiconductors. For example, the quality, reliability and performance of semiconductor components depend on high-purity nitrogen. Producing this using an in-house air separation plant is very energy intensive.
During the lithography process, tiny structures are transferred to the surface of the wafers using energy-intensive exposure devices. As the production of semiconductors is almost completely automated, there is great potential for saving energy in the automation technology used. By regularly monitoring your automation equipment, you can identify inefficient processes and uncover potential savings.
2. Materials management: resource efficiency as a success factor
The efficient use of raw materials and consumables plays a decisive role in cost optimisation in semiconductor production. Companies can reduce their storage costs by precisely managing their inventory, thus avoiding having excess stock. A targeted and efficient use of materials reduces your operating costs and increases success in terms of your economic and environmental performance.
By optimising and precisely applying expensive photoresists, for example, you can achieve high-quality results and minimise waste. The use of process gas in the etching and coating process opens up another potential for savings . The gas flow is safely and reliably controlled by special stainless steel valves.
Thanks to clever system configuration, with advanced process control and monitoring systems, the consumption of process in semiconductor production can be optimised. This enables you to achieve considerable cost savings in your company.
3. Maintenance strategy: prevention instead of reaction
Carefully planned and regular maintenance minimises unplanned downtimes in the production of semiconductors and the associated loss of wafers in the process.
AI systems and their algorithms will enable you to analyse large volumes of production data and identify patterns that indicate anomalies or deviations. This allows you to identify potential problems at an early stage and react quickly through predictive maintenance. Predictive troubleshooting keeps product quality and efficiency at a high level, prevents scrap and helps to maximise the output of the entire production process.
4. Environmental management: combining sustainability and cost savings
Managing waste effectively in semiconductor production is important from both an environmental and an economic point of view. By handling waste and chemicals correctly, you can not only achieve sustainable goals, but also considerable cost savings. Special valves enable gas flows to be precisely controlled and regulated, ensuring an efficient and effective filtering of exhaust gases.
Certain chemicals and substances used in semiconductor production can also get into the wastewater. Using specific agents and the use of filters, these substances can be effectively removed from the wastewater and separated in an environmentally friendly manner.
Conclusion: increasing efficiency and sustainability in semiconductor production
Understanding the factors influencing operating costs is crucial for semiconductor manufacturers so they can reduce them, thereby acting sustainably and successfully in the long term. Even small factors can have a big influence.
The ways in which you can significantly reduce your company's operating costs and thus maximise profitability and competitiveness are through optimised plant maintenance, improved and energy-efficient processes, effective environmental management and strategic material management in procurement, storage and production. Taking a comprehensive view of all aspects that can optimise costs and increase output throughout production are the keys to success in the semiconductor industry.
About the author
Tobias Glattbach
Global ISM Electronics
Festo SE & Co. KG
