Semiconductor manufacturing training solutions

An onboarding program for new hires in the semiconductor manufacturing industry should cover essential topics to provide a comprehensive understanding of the fundamentals and the manufacturing processes of semiconductors.

An introduction to semiconductor physics, including concepts such as band theory, doping, and carrier mobility, and a review of the semiconductor industry's value chain set the stage. Next, an overview of semiconductor materials, device structures, and device characteristics helps new hires grasp the basics.

Moving on, an exploration of semiconductor manufacturing processes, including photolithography, etching, deposition, and packaging, provides insight into the intricacies of production. An introduction to the operation and maintenance of manufacturing equipment, as well as metrology tools, to build familiarity with the essential tools of the trade.

Cleanroom protocol and safety standards are crucial to ensure contamination control and workplace safety. Quality control principles and data analysis techniques round out the program, emphasizing the importance of product quality and process optimization.

By focusing on these main topics, new hires gain a solid understanding of semiconductor manufacturing, ready to achieve success in the industry.

Semiconductor manufacturing is characterized by digitalization, since it forms the basis for Industry 4.0 technologies such as the Industrial Internet of Things (IIoT), cyber-physical systems, additive manufacturing, augmented reality (AR), virtual reality (VR), artificial intelligence (AI), big data analytics, and other advanced innovations. In this context, the digitalization of factory automation technologies optimizes production processes and enhances operational efficiency

Mechatronics, a multidisciplinary field combining mechanical, electrical, and computer engineering, is essential for understanding and maintaining the complex machinery and robotic systems utilized in semiconductor production. Furthermore, as manufacturing facilities move toward interconnected production lines, operators need expertise in networking technologies to ensure seamless communication and coordination between equipment and systems. MES platforms play a pivotal role in optimizing production processes, scheduling, and resource allocation, requiring operators to be proficient in their operation and utilization.

Additionally, with an ever greater focus on  energy efficiency, employees must have knowledge of energy management principles, particularly in areas such as electrical systems and compressed air usage, to minimize energy consumption and reduce the environmental impact of semiconductor manufacturing facilities.

Robots, both industrial and mobile, have become integral components of the modern fab environment.

Industrial robots handle silicon wafers throughout the manufacturing process. They are used in semiconductor assembly and packaging operations to pick and place components with high precision. Industrial robots assist in etching and deposition processes by precisely positioning substrates and masks in process chambers. They can be found in metrology and inspection, and even cleanroom maintenance. Depending on the task, various robots are used, such as articulated, cartesian, collaborative (cobots), and others.

Autonomous or semi-autonomous mobile robots are also used for material handling (transporting materials, components, or finished products between different areas of the manufacturing facility), inventory management (tracking and locating semiconductor wafers, components, or tools) and inspection tasks.

PLCs are widely used in semiconductor manufacturing systems to control and coordinate various processes. Proficiency in PLC skills is essential for individuals working in industrial automation, manufacturing, and process control, enabling them to effectively program, operate, and maintain PLCs to optimize production processes and ensure the smooth operation of industrial machinery.

Understanding PLC hardware components is essential for selecting, installing, configuring, and troubleshooting PLC systems. Proficiency in PLC programming languages is vital for developing, testing, and debugging PLC programs using professional programming software. Additionally, integrating safety features into PLC programs, such as emergency stop circuits, interlocks, and safety-rated relays, is crucial.

Since PLCs are often integrated in an industrial network, technicians must also know how PLCs interface with various manufacturing equipment and systems in semiconductor fabs. This includes understanding sensor technologies, actuator types, communication protocols, and data exchange mechanisms used to integrate PLCs with equipment such as robots, vacuum chambers, chemical delivery systems, and metrology tools. Configuration of PLC communication interfaces, setup of network connections, and troubleshooting communication issues require a solid understanding of industrial communication protocols.

Furthermore, employees should be capable of collecting, processing, and analyzing data generated by the PLCs to monitor process performance, identify deviations, and optimize production processes.

Electrical systems play a vital role in powering up, controlling, and monitoring semiconductor manufacturing equipment and processes.

All technicians need a solid understanding of the basics of electrical engineering and electronics, such as electrical principles, including voltage, current, resistance, power, and circuits. Training on electrical safety practices, including lockout/tagout procedures, proper use of personal protective equipment (PPE), and precautions for working with high voltage equipment is paramount.

Electric motors are widely used in machines and systems in semiconductor manufacturing since they are efficient, precise, and reliable. Their ability to deliver a consistent performance, coupled with low maintenance requirements, makes electric motors a preferred choice for powering critical devices such as robotic arms, conveyor systems, vacuum pumps, and wafer handling systems in semiconductor manufacturing plants.

Electric motor controllers provide efficiency, precision, reliability, and safety across production processes. Their speed, torque, direction, and position can be regulated using basic technologies such as relays, stepper and servo drives, variable-frequency drives, PLCs. etc.

Electronics skills are indispensable for the semiconductor manufacturing workforce, as it enables them to grasp the underlying principles of semiconductor technology, optimize manufacturing processes, operate sophisticated equipment, and troubleshoot and repair, even circuit boards. Proficiency in circuit theory, power electronics, analog electronics, and digital electronics is particularly relevant in semiconductor manufacturing, where intricate electronic components and systems are used in production equipment.

Pneumatic and electropneumatic components are commonly used in semiconductor manufacturing equipment for various purposes, including actuation, control, and manipulation. Vacuum technology ensures wafers are aligned and stable during photolithography and etching processes. Pneumatic pumps and valves ensure gases and chemicals are supplied precisely and consistently.

Given the need for high precision, complex automation, and data-driven optimization in semiconductor manufacturing, digital pneumatics—pneumatic components equipped with digital control technology—offers enhanced functionality, precise control, and communication capabilities.

These technologies enable cost-effective, high-performance solutions with rapid response times, simple installation and maintenance, cleanliness, and adaptability. Additionally, pneumatic systems are non-sparking and intrinsically safe, making them suitable for use in hazardous environments commonly found in semiconductor manufacturing facilities.

Sensors play a critical role in monitoring, controlling, and optimizing various processes, equipment, and environments to ensure the production of high-quality semiconductors. Sensors monitor temperature, pressure, flow, level, optical properties, vibration, position, among others, providing real-time feedback on process conditions. This enables operators to maintain optimal parameters and promptly detect any deviations that could impact product quality.

In recent years, smart sensors and their seamless integration into industrial control systems have elevated automation to new levels, offering enhanced efficiency, improved accuracy, and reliability.

Although semiconductor fabs are highly automated and high-tech environments, basic skills are required to operate machines and systems:

Pumps and piping systems are integral components of semiconductor manufacturing facilities They facilitate various processes and operations, such as delivering chemicals and gas, cooling, vacuum generation, and waste management.

Mechanical drive systems rely on components (e.g. belts, chains, gears) that transmit power and motion from motors to moving parts within semiconductor processing machinery.

Industrial electrical wiring plays a critical role in providing power and connectivity to various machines and systems so they can operate reliably and efficiently.

Basic dimensional metrology and proper use of common hand tools are essential for efficient maintenance and repair tasks on production equipment and machinery.

In semiconductor manufacturing, heating, ventilation, air conditioning (HVAC), and refrigeration systems are essential to maintain the precise environmental conditions necessary for high-quality production. These systems control the temperature, humidity, and air quality, all of which are essential for the manufacturing process.

Technicians must be proficient in using monitoring tools to track these environmental metrics. Their technical aptitude must extend to understanding HVAC control systems and how these systems integrate with other facility systems and processes. They must also understand basic refrigeration concepts, such as the fundamentals of thermodynamics and the refrigeration cycle.

Semiconductor manufacturing requires a variety of process instrumentation and control instrumentation to ensure precise control, monitoring, and optimization of the process variables such as flow, level, pressure, temperature, pH, and conductivity. Common examples include flow meters, pH sensors, and pressure controllers. Transmitters, valves, and other field devices are also crucial components within these process loops.

Supervisory Control and Data Acquisition (SCADA) and Distributed Control Systems (DCS) are examples of automated control systems adjust process parameters based on feedback from sensors to maintain desired conditions and achieve consistent semiconductor quality. These systems regulate gas flow rates, chemical dosages, and equipment settings with high accuracy and repeatability. SCADA systems typically monitor and visualize process data in real time, while DCS systems offer centralized control and coordination of process equipment and operations.

Semiconductor manufacturing relies heavily on ultra-pure water with minimal contaminants. Ultra-Pure Water (UPW) systems use advanced purification methods like reverse osmosis, deionization, and filtration to meet stringent quality standards. This purified water is integral to various manufacturing processes, including wafer cleaning, chemical mixing, and rinsing. Maintaining the quality and quantity of process water is paramount for consistent and dependable production procedures.

Additionally, water is also a crucial coolant, safeguarding equipment against overheating and ensuring optimal performance. Given that semiconductor manufacturing generates wastewater containing diverse chemicals and contaminants, effective treatment processes are essential before the water is discharged, recycled, or reused. This minimizes water consumption and the environmental impact, and ensures manufacturing practices are sustainable.

Operational excellence and product quality are critical pillars of semiconductor manufacturing, necessitating a thorough understanding of various principles to ensure efficiency, reliability, and product excellence.

By having an understanding of lean production concepts, including waste reduction, continuous improvement, and value stream mapping, employees are able to optimize processes and eradicate inefficiencies throughout semiconductor manufacturing.

Proficiency in statistical process control (SPC) techniques helps operators to monitor and manage manufacturing processes, maintaining consistency and swiftly identifying deviations that could compromise product quality.

Knowledge of total productive maintenance (TPM) principles is indispensable for guaranteeing equipment reliability, minimizing downtime, and maximizing overall equipment effectiveness (OEE) in semiconductor manufacturing facilities.

Moreover, proficiency in additional topics such as Poka Yoke, 5S workstation organization, value stream analysis and mapping, and Six Sigma methods further enriches employees' skill sets and enhances manufacturing operations.

Providing equipment that mirrors the environment found in semiconductor fabs ensures that students can familiarize themselves with industry-standard machinery and technology.

Offering practical exercises, experiments, and projects that simulate real-world manufacturing scenarios allows students to gain valuable hands-on experience.

Utilizing multimedia courses, simulation tools, virtual labs, and augmented reality applications enhances the learning experience, caters to different learning styles, and facilitates understanding of complex concepts.

Adapting training to students from diverse backgrounds and with different career aspirations ensures that each individual receives tailored education suited to their needs and goals.

Tracking students' progress, identifying areas for improvement, and providing guidance and support throughout the training program ensures that students are continuously developing their skills.

Emphasizing the development of soft skills such as communication, teamwork, and adaptability is essential for success in the collaborative and fast-paced environment of semiconductor manufacturing.