equity and inclusion

The drive to scale nodes towards physical limits, known as "More than Moore," and the adoption of 3D architecture in chip integration strategies for advanced logic and memory applications has led to unprecedented demand for high-quality dependable materials solutions. With the aid of digital solutions, the process is expedited with higher quality and efficiency.SEMI spoke with Thorsten vom Stein, Director, Head of Process Design Semiconductor Materials at Merck KGaA, Darmstadt, Germany, about how materials innovations and advanced packaging can contribute to smarter supply chain solutions for a sustainable ecosystem.More insights into key aspects of 3D architecture in chip integration and heterogeneous integration will be shared at the Advanced Packaging Conference (APC) during SEMICON Europa 2024, Nov. 12-15 in Munich, Germany. Registration is open.SEMI: What makes the digitalization of chemical process design for semiconductor materials manufacturing so challenging at a technology level? Vom Stein: The primary challenge in digitalization of process design is achieving data rich experimentation and design flexibility from the start. When we begin the process design for a novel material solution, the freedom of design needs to be very high for optimal outcomes. For example, to identify the best sequence of unit operations to achieve best process intensification, do we need a distillation or extraction after the reaction to meet the purity requirements? At the same time, the samples from these early process trials need to have purity levels and process reliability standards for high-volume manufacturing of routine production in order to meet the requirements of our customers’ leading-edge chip integration strategies. We address this need by executing data rich experimentation starting with first trial, and thereby establish “production ready” data density in the lab.To avoid confining our design space, we therefore need highly “sensorized” and automated modular lab equipment that can give us the data density we need and flexibility at the same time.SEMI: Are data-driven approaches also applied to streamline manufacturing processes? Vom Stein: Yes, data-driven approaches are key to driving cost, quality, process reliability and sustainable excellence. As we scale up from lab experiments to high-volume manufacturing—often times increasing volumes by two or three orders of magnitude—we scale the process model virtually ahead of its physical twin to de-risk these major scale-up steps. An example of this is simulating the effect of reactor geometry on the impurity profile.Establishing this handshake between the physical asset and the process model early in the development has a lot of benefits for sustained cost efficiency of the future manufacturing process. For instance, it allows for optimization of yield and cycle times to the existing asset infrastructure. Furthermore, we can achieve quality reliability critical to our customers by establishing end-to-end correlation models that link the quality of incoming raw materials to finished good impurity profiles.Finally, we can achieve the lowest possible carbon footprint and minimize waste streams and energy intensity via process intensification by matching the unit operation sequence to the specific thermodynamics and kinetics of the process.SEMI: How can advanced packaging contribute to the pursuit of net zero? Vom Stein: Ultimately in a successful process design, we aim to achieve the maximum yield of value-added product with minimal input of resources and raw materials. So, there is an intrinsic synergy between highly intensified processes and their carbon footprint. The digitalization of process design allows us to track the CO 2 footprint during every iteration of the design. Establishing this tracking as a routine design KPI is one of the key initiatives to drive net zero semiconductor material solutions.In addition, advanced process design is a key enabler for circular value streams. We are currently working on multiple projects to recycle waste streams and re-feed them as raw materials in our processes. We are also exploring how our chemical process technology can aid our customers’ recycling efforts such as reusing lithography cleaning solvent waste streams.SEMI: In your previous talks, you emphasized the importance of diversity, equity and inclusion (DE I). How is this related to the digital revolution? Vom Stein: In the not-so-distant past, my team consisted mainly of process chemists and engineers. Now, we are working with data scientists, model developers, automation experts and many more substance matter experts on our projects. This work requires an inclusive culture to maximize the impact of these diverse sets of insights and disciplines.We also must acknowledge that, in many instances, we are exploring unchartered territory that requires a “leap of faith” culture trusting in digital models. Imagine, for example, a production plant director who is used to a stepwise physical scale-up, now being onboard with skipping physical scale-up steps by using predictive process models. It takes time to really establish a trust in the “power of data.” This type of culture is championed at Merck KGaA, Darmstadt, Germany on all levels: from CEO to the production operator. Our DE I Report showcases how we continuously build belonging for over 64,000 employees across the globe.SEMI: Merck KGaA, Darmstadt, Germany is a key contributor to semiconductor innovations. How important is it for Merck KGaA, Darmstadt, Germany to collaborate with other industry leaders to achieve goals in matters such as sustainability and DE I? Vom Stein: Collaboration with our customers and OEM partners is a key piece of achieving the molecular precision necessary to drive technology evolution that serves as the backbone to society. More and more, we need to link our material solution manufacturing process to the process parameters of the tools in the fab, ultimately improving the chip yield of our customers. To transition from the nanometer era to the angstrom era, we must establish these process correlations end to end along the value chain, which is why we are heavily engaged on our Athinia collaboration framework.Besides technology enablement, sustainability is the next avenue where cross value chain collaboration is a must to lower the CO 2 and energy footprint of our industry. To this end, we have started a joint program with Intel on AI-enabled sustainable semiconductor processes.The importance of industry collaboration is why I was so honored to participate at SEMICON Europa together with representatives from leading companies.SEMI: What did enjoy about SEMICON Europa 2023 that you would like to experience again in 2024? Vom Stein: I was really impressed by the SEMICON Europa 20 Under 30 recognition program launched during the show. The program honored the brightest young leaders who have demonstrated success in their careers in the microelectronics supply chain. We were very happy with the acknowledgement of one of our brightest minds at Merck KGaA, Darmstadt, Germany, Balazs Bordas, Digital Twin Implementation Lead. He has been instrumental for many of our pioneering efforts in this space.Such recognition programs are very important for our industry and can make a significant difference in the perception of the semiconductor industry and its ability to motivate and attract more talent. I personally hope to see similar programs in the years to come.Additional resources:Learn more about diversity and inclusion at Merck KGaA, Darmstadt, Germany.Learn more about Merck’s KGaA, Darmstadt, Germany modular lab automation approach.Merck KGaA, Darmstadt, Germany sponsored SEMICON Europa and SEMI Advanced Packaging Conference in 2023. Thorsten vom Stein is Director, Head of Process Design Semiconductor Materials at Merck KGaA, Darmstadt, Germany. Based in Darmstadt, Germany, he holds a PhD in Chemistry from the RWTH Aachen University and has extensive experience in Catalysis, Materials Science, Process Development and Value Chain Innovation.Serena Brischetto is Director of Marketing and Digital Engagement at SEMI Europe.

The key to driving change is getting men involved in closing the gender gap and encouraging more equitable workplaces.

Nikki Zaahir joined SEMI last year as senior program administrator on the SEMI Works team after spending the last 15 years designing, coordinating and directing programs that help people develop job skills and find full-time employment. Her career includes roles at the Department of Defense, the National Security Agency, America Works and Vehicles for Change.I spoke with Nikki about her passion for workforce development as we celebrate Black History Month.Williams: What does Black History Month mean to you?Zaahir: Black History Month means to me an opportunity to highlight the overwhelming influence of the inventions that Black Americans contributed to this country. Of all the Black history shared this month, it’s the inventors that have always intrigued and excited me the most. I grew up in a home with parents that taught my siblings and me the history of our culture every day. However, each February I was allowed to research and share my own list of what we called “little known Black history facts.” A couple of my favorites from my childhood are Lonnie Johnson, who invented the Super Soaker water gun, and Alexander Miles, who developed automatic elevator doors in 1887. Frankly, Black History Month reminds me to be proud to be Black and to take a moment to pay homage to the excellence and fortitude of my people.Williams: Where are you from, and where did you go to school?Zaahir: I am from the suburbs of Maryland right outside of Washington, D.C. I grew up in a military family. My father was the first black 1st Sargent in his transportation company. His unit was responsible for transporting heavy artillery equipment around the world. I went to Meade Senior High School on the army base of Fort Meade.Williams: How did you get started in the semiconductor industry?Zaahir: While in the 11th grade, I was actively recruited by a semiconductor company that had recently won a National Security Agency government contract at Fort Meade to make semiconductors for the military.I excelled in English and Science and met the requirements for the work study, which allowed me to spend half of my day in school and the other half at a work study assignment. The company tested a couple of hundreds of students and I was one of the 34 chosen for the career development program. I worked as a technician responsible for the fabrication and processing of the semiconductor wafer. My favorite steps of this process were the spin on glass and gasses chambers in the fab. What lit a fire in me was the realization that there is a whole world of technology opportunities that people like me were unaware of.Nikki Zaahir, in her former role as National Director of Workforce Development and Training at Vehicles for Change, with interns training to be certified automotive technicians.Williams: Did you have any mentors or sponsors who were particularly meaningful as you developed your career?Zaahir: I’ve been very fortunate to be mentored and supported by many people on my professional journey. Peter Cove and Dr. Lee Bowes are a social activist couple who own America Works. They were instrumental in my understanding of workforce development by teaching me that self-sufficiency through gainful employment can change generational poverty. However, the most meaningful people to me are those whose lives I’ve had the absolute pleasure to help change. For example, at Vehicles for Change, I created a social enterprise designed to assist returning citizens (people formerly incarcerated) with training and job placement. In three years, we placed 200 men and women in the workforce with no one reoffending or returning to prison within three years. What made this group of individuals special is that I chose to focus on violent offenders that served 10 years or more in prison.Williams: What motivates you in your work?Zaahir: What drives me is helping people become aware of careers that could not only change their lives but the lives of their families, and waking up every day determined to be that conduit of information and job opportunities.Williams: What is wonderful and challenging about workforce development?Zaahir: Inspiring people to consider educations and careers that may have never been on their minds is the most rewarding aspect of workforce development. To see people who have felt left out of training and employment opportunities due to their backgrounds or lack of higher education take charge and pursue educations and careers that before were only a dream makes this work worth it. On the other side of that, convincing someone who has felt left behind or unworthy of a better life for themselves and their family can be challenging.Williams: Is there a particular story about someone you’ve worked with or helped that you’d like to tell?Zaahir: Eight-time Grammy award winning artist Lauryn Hill of the legendary hip hop group The Fugees once said “In my travels all over the world, I have come to realize that what distinguishes one child from another is not ability, but access. Access to education, access to opportunity, access to love.”I have been blessed beyond measure to work with and help so many people at this point in my career. What I’d like to share is while talent is abundant, access and opportunity are not. That is the story.Williams: What is something unusual about you that people might not know?Zaahir: I’ve studied at the Arthur Findlay College, the world’s foremost college for the Advancement of Spiritualism and Psychic Sciences. Oh! the ghost stories I could tell.Williams: What would you tell young people interested in working in the semiconductor industry?Zaahir: In this industry, you will develop transferable skills for almost any career in manufacturing or production and the ability to make a salary that will provide the opportunity to afford living in safe neighborhoods, reliable transportation and vacations! You can pursue a wide range of skills, training, education and other professional development opportunities in this industry – all while maintaining a healthy work-life balance.Michelle Williams is deputy director of the SEMI Foundation.