Process optimisation: avoid fluctuations in the production process
Optimising the production process for semiconductors is a decisive factor in increasing output. By analysing and optimising process parameters and sequences, you can increase efficiency and output. The process parameters at the machine level include, for example, temperature, pressure, exposure and etching time. This is where data analysis and artificial intelligence can help you to improve processes and thus increase output.
Data analysis and continuous improvement
Analysing production data and continuous improvement are key steps in increasing output in the long term. With data analysis tools such as machine learning, for example, companies can identify patterns and trends and eliminate inefficient processes or quality problems. Artificial intelligence is an excellent resource, as it identifies possible deviations based on a large amount of data. The data will provide a basis that you can use to implement specific improvement measures to achieve predictive quality, i.e. predictable product quality.
Preventive maintenance and machine calibration for optimum handling of semiconductors
The condition and precision of the production systems also play an important role: for example, are the photolithography systems, systems for chemical vapour deposition, etching systems, etc. in good working condition? Timely maintenance, servicing and calibration of production plants is essential to avoid failures and increase output. Artificial intelligence is becoming increasingly important here too, as it precisely registers deviations of the parameters from the hysteresis value and thus makes predictive maintenance possible.
Training and further education of employees
Employees also play a crucial role in increasing productivity in semiconductor production. Regular basic and further training can help to boost process understanding, identify optimisation potential and find more effective solutions.
Semiconductor production requires cleanroom conditions
As even the smallest particles or contamination can impair the output, the semiconductors are produced in rooms in cleanroom class ISO 1 to ISO 5. It is essential to control the temperature, air quality, particle contamination and humidity, as well as to have a product portfolio suitable for the cleanroom. Effective cleanroom protocols, regular maintenance of ventilation and filtration systems and staff training in cleanroom behaviour are required.
Quality of the raw materials
The quality of the raw material used, in particular the silicon wafers, is decisive for production output. Contamination or defects can lead to faults and increased scrap. Quality control of the materials is therefore absolutely essential.
Conclusion
Increasing output in semiconductor production requires an overall approach that takes both technological and organisational aspects into account. By ensuring raw material quality, optimising the production process, training staff, and applying preventive maintenance and data analysis, for example with artificial intelligence, you can maximise the output of the functional chips obtained from a semiconductor and significantly increase your output. A culture of continuous improvement is the key to long-term success.
About the author
Torsten Schulz
Head of Electronics Global Industry Segment
Festo SE & Co. KG
