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SEMI met with Heinz Martin Esser, managing director at Fabmatics GmbH, to discuss how existing 200mm semiconductor fabs can master the challenges of a 24x7 production under highest cost and quality pressure by implementing intralogistics automation solutions. The two spoke ahead to his presentation at the Fab Management Forum at SEMICON Europa 2018, 13-16, November 2018, in Munich, Germany. To register for the event, click here. SEMI: Looking at the latest production capacity data for 2018 – it is a 200mm fab boom. Growing demand for analog, MEMS and RF chips continues to cause acute shortages for both 200mm fab capacity and equipment. Do you think this trend will continue the next years or is it only a short term run on 200mm fabs?Esser: We at Fabmatics believe in a long-term trend. The emergence of the Internet of Things and growing digitalization in all areas of life will continue to increase demand for integrated circuits (ASICs), analog ICs, high-performance components and micro-mechanical sensors (MEMS) in the coming years. Many of these semiconductor elements should be produced in 200 mm fabs.SEMI: How does Fab automation contribute to increase capacity of existing, mature 200mm fabs?Esser: We are convinced that fab automation is one of the greatest potentials for older 200mm factories to effectively master increased demand, increasing efficiency, quality assurance and flexibility at the same time. In particular, material flow automation, which is often the missing link between existing equipment in different production areas, can help increase productivity in an elementary way.If you analyze how long valuable tools typically wait for loading and unloading, you can see a direct effect of the intralogistics automation system, which leads to a significantly higher utilization of process equipment by making the material flow independent from human performance. Additional side effects such as reduced cycle time, stable fab flow factor or flattened WIP shafts further increase the contribution of material flow automation to get the most out of existing mature factories. Older does not mean obsolete.SEMI: What are the biggest challenges for a successful implementation?Esser: There is no single challenge when you automate an existing mature fab. Instead, you face a whole variety of challenges you have to tackle, ranging from historically grown non-aligned fab layouts over non-linear material flows and older non-standardized equipment to “automation unfriendly” fab environment. Also you should not underestimate the efforts to overcome the practice manual fab operation people in the cleanroom are so familiar with for many years. Before doing automation you have to think automation, i.e. you have to question all processes to make them ready for automation.SEMI: What are the key drivers to automate a mature fab today: costs, process stability, quality or a combination of them?Esser: This question should be better asked to our customers, but we believe it is a mix of many impacts. Most likely everybody sees the cost reduction at first, but we get more aware of process and performance stability as well as quality requirements – and here our customers’ play the most important role – become more and more focused.SEMI: What do you expect from SEMICON Europa 2018 and why do you recommend attending the Fab Management Forum?Esser: This year SEMICON Europa will co-locate with electronica. So it`s going to be the greatest trade fair for electronics manufacturing in Europe. We will meet innovators and decision-makers across the whole electronics supply chain. The Fab Management Forum addresses a highly topical question that concerns all semiconductor manufacturers not only in Europe - how to handle complexity and enable the necessary flexibility to cope with customers' needs. High-ranking speakers will give an insight into the latest technologies and best practices. I am looking forward to the lively exchange with the participants and taking away new impulses for our business. Heinz Martin Esser is managing director at Fabmatics GmbH, responsible for sales and marketing, customer service and administration. He studied supply engineering at the University of Applied Sciences in Cologne and later earned a university degree in business administration. Serena Brischetto is a marketing and communications manager at SEMI Europe.
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Ahead of his presentation on the future of wearables at the European MEMS Sensors Summit 2018, 19-21 September in Grenoble, France, SEMI spoke with Dr. Peter Weigand, vice president, Business Strategy and Portfolio Management, Bosch Sensortec GmbH. Dr. Weigand gave a glimpse into insights he’ll share at the event.1. Wearables such as smartwatches, fitness trackers or hearables are becoming ubiquitous – but what are the must-haves for wearables for daily use by wearers?We see that users nowadays want to track their activities such as steps walked, calories burnt and floor levels “climbed” on a daily and holistic basis. “Quantifying yourself” is becoming an overall trend in our society with health, fitness and well-being continuously gaining in importance. This is only possible if information about activities is delivered comprehensively in an accurate manner. Therefore, at Bosch Sensortec we provide MEMS sensors that measure the user’s activity very precisely. For example, the smart sensor hubs BHI260 and BHA260 provide sophisticated in-sensor algorithms (e.g. activity recognition) with very low latency and guaranteed performance due to the real-time nature of the embedded software. From the system manufacturer’s perspective, “quantifying yourself” on a 24/7 basis means that the device has to be “always-on.”However, these always-on functions usually consume a lot of battery power, which poses challenges to the manufacturers and system designers, as the battery capacity is usually small due to the size of the wearable. This shows two other must-haves for the users nowadays. First, the compact size of the device. While smartphones have become larger, users of wearables benefit from the devices’ small size and their low weight, offering the possibility to wear them directly on the body. Therefore, we design the footprint and height of our MEMS sensors as small as possible to ensure the compact size and the ease of integration into new, stylish types of wearables. For example, the BMP388, measuring only 2 x 2 x 0.75 mm³, qualifies as the world’s smallest barometric pressure sensor. The second requirement in this regard is long battery life. Users do not want to charge their wearable device every other day, as this would also impede the always-on activity tracking aspect. At Bosch Sensortec, we hence provide MEMS sensors that run at ultra-low power to ensure always-on endurance and a long battery life. The BMA400 is an ultra-low power acceleration sensor that draws ten times less current than existing accelerometers.2. Are there any other user requirements for wearables?Yes, we see for example that just tracking the number of steps or the calories burnt is not enough anymore. Users require multi-functional devices that also provide information that can be used to monitor sleeping behaviour, navigate in cities, or prepare your smart home for your arrival. We are equipping our sensors with more features and developing new types of sensors that add new functionalities to wearable devices. For example, we have developed a smart watch Projection Module that can project information on the back of the user’s hand for an additional, enlarged display. While smart watches are rising in popularity, demand for basic wristbands is waning. Users are paying more attention to device design. Like clothing, the look and feel of the device should support the user’s individual style.At the same time, with more fashion brands are entering the wearables market we are providing sensors that are easy to integrate into new types of wearables such as hybrid watches. Our products feature a small form factor to ensure flexible, simple design-in. For example, the new BMA400 acceleration sensor easy to design into various applications. Finally, to conform to the user, the wearable must adapt to the user’s individual habits and motions such as learning different gestures, requiring the devices to be not only smart but increasingly intelligent with artificial intelligence (AI). We are providing sensors, such as the BHI260, with embedded, local intelligence with advanced algorithms that enable devices to learn. We are developing intelligent software solutions that use deep learning, enabling device to adapt to the user’s individual behaviour.3. What current techniques are design engineers using to reduce power consumption of wearables?Several techniques are being developed to reduce power consumption. The goal largely is to reduce the power draw of components that are always-on, such as the screen in a smartwatch. In activity trackers, the motion sensor is always on to sense, track, classify and store motion data. Reducing the power needed to operate these features will cut total system power consumption as well. A good example is our BMA400 accelerometer that has a current consumption of less than 1 µA in full operation.At the same time, it independently processes sensor data. For example, the device converts the three-axis motion sensor data stream into step counting events. This allows the main (host) microcontroller to remain in the stand-by mode required for activity tracking and to be activated by the accelerometer to deliver full power only, say, every 100 steps. The sensor, rather than the microcontroller, manages the overall duty cycling of the microcontroller to reduce system power and increase overall efficiency.4. What alternatives are engineers exploring to reduce power consumption? What is the role of intelligence directly within sensors for local processing capabilities in wearables?We have seen how the BMA400 can reduce power by integrating the motion classification functions. We can take this concept further by integrating a microcontroller that’s specifically tailored for low-power sensor data processing, such as the “fuser core” that Bosch Sensortec uses within its smart sensor hubs such as BHI260 or BHA260. The built-in sensor data fusion and machine learning hardware accelerators make it uniquely suited to reduce overall system power. The concept of edge computing has been around for many years, but only in this and the previous sensor generation with built-in local intelligence are we reducing the full power profile of the wearable device. Our sensor architecture design allows us to process the power locally in the MEMS sensor without waking up the main application processor.5. What technologies are you developing to lengthen battery life without compromising performance? We are continuously improving the MEMS and ASIC designs of our sensor portfolio to drive ever higher power efficiency. The BMA400 draws 10 times less current than existing accelerometers while delivering solid high performance (e.g. low-noise data). 6. Wearable device feature and performance requirements are continuously rising. Will batteries need to be larger to support these requirements? Since the beginning of the portable consumer electronics, improving batter life and reducing chip power consumption have been parallel efforts, a trend we expect to continue. However, we expect a greater focus on the overall system power reduction with sensors managing the power, turning on and off microcontrollers, radios (including GPS) and displays in wearable devices.7. What do you expect from European MEMS Sensors Summit 2018 and why do you recommend attending in Grenoble?The European MEMS Sensors Summit is a very important platform for us. It is an opportunity to meet partners, customers, industry leaders, to exchange ideas and to get new insights and thus to ultimately refine our solutions for our global customer base. Our ultimate goal is to improve people’s individual lifestyle and well-being.Serena Birschetto is a marketing communications manager in SEMI Europe.
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The MEMS industry has huge growth potential. Will MEMS fabrication act as a bottleneck to continued expansion or a critical conduit to achieving that potential? Slow development cycles, multiple fabrication platforms and high cost for small R D volumes are barriers to rapid development of new products. Understanding the special features of MEMS fabrication — with its many ecosystem options — will help your company to navigate successfully these challenges as you more quickly develop new and unique products.The sheer diversity and varying requirements of MEMS devices and the one product, one process approach are the root causes of most MEMS fabrication challenges. While a single approach will not suit all companies, forming an ecosystem that leverages different companies’ expertise is one of the best ways to address these challenges. However, knitting together this ecosystem is difficult because having multiple partners in the mix only works if the entire supply chain follows common basic design rules and a common top-level technology development roadmap.Because establishing these commonalities takes time and effort, many large- and medium-sized companies prefer to own their supply chain, regardless of the costs. In contrast, emerging companies that cannot support heavy capital investments in new equipment will inevitably find foundries that have all the equipment in place — as well as a wide variety of MEMS processes — a more attractive option. As you embark on a MEMS fabrication journey, which options should you consider to stay ahead of the pack?Finding ecosystem partnersSince there are so many different technology choices that make process integration difficult in MEMS fabrication, technology know-how is the key to developing unique products in time. If you are not able to own your supply chain, you must find ecosystem partners whose expertise both matches and complements your technology (Table 1). Table 1: Ecosystem options as a function of company expertise. 1=Excellent fit 2=Good fit 3= Ok fitYou must also understand how your company can add value — either directly to the end-product or to the other partners in the ecosystem. Above all, there must be trust among partners. A lack of mutual trust will lead to inadequate information-sharing and cumulative knowledge-gathering — slowing problem-solving and/or causing excessively long development cycles. Option 1: Own your supply chainWhile few companies can support Option 1 — having the whole supply chain in-house (like Bosch or STMicroelectronics) — the benefits are many: all know-how will be contained within the company, IP is easy to protect, and supply-chain management is simpler. However, this model demands a significant investment in tools and, in the long run, substantial effort and money to remain technologically competitive in each part of the supply chain.Option 2: Outsource the ASICYou might opt for a fully owned supply chain — outsourcing only ASIC fabrication and possibly ASIC design and assembly. This option requires significant expertise in MEMS technology, freeing you from the limitations of a fabless operation model as you gain more control of MEMS fabrication processes. It also offers more IP protection than you would have with a foundry.While the disadvantages of Option 2 are similar to the fully owned supply chain model, you can mitigate them by outsourcing part of the MEMS chip fabrication supply chain or outsourcing some development to wafer supply companies that can handle the customer-designed embedded structures inside the wafer and/or multi-stack wafer packages. Outsourcing will shorten the process flow and reduce the amount of capital required for growth. A third outsourcing option is to farm out especially difficult or incompatible steps, delivering multiple benefits such as access to better materials, including specialized polymers – which are typically more expensive than silicon – and precious metals, such as gold or platinum, which can contaminate equipment during thin-film deposition processes.Options 3-4: Foundry modelsWhile more companies still own the whole supply chain or outsource the ASIC portion of their device than use MEMS foundries, the MEMS foundry solution is still an especially good option for cost-conscious companies. If you cannot afford the substantial investment needed for new tools and/or advanced materials or your product requires rapid scaling-up because of short lifecycles, you should explore foundry solutions. There are two main types: pure-play foundries (Option 3) and a foundry with design services and its own IP (Option 4). Option 3 offers no design services, nor does it provide its own designs. It is an excellent choice for a MEMS design-based company lacking its own MEMS fabrication line. However, if your company lacks in-depth knowledge of MEMS design, Option 4 will give you design support and possibly some IP as well. Option 5: Buy the MEMSOption 5 is to buy ready-made MEMS chips and use them as the foundation to build your component. This is solid choice if your company is high in the value chain or has system-level expertise.In the future, MEMs ecosystem players will win by offering both design-library development and a supporting portfolio of MEMS process design kits — just as the IC industry now does. This winning approach will significantly shorten the MEMS product-design cycle – from idea to process development and finished product – and will ultimately change the rules of the game for the MEMS fabrication industry.Based in Vantaa, Finland, D.Sc.(Tech.) Heikki Holmberg develops new business opportunities for Okmetic’s high-performance silicon wafers. He also manages Okmetic’s research portfolio, including European Union- and nationally funded research projects. For more information, visit: https://www.okmetic.com/
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