QUALITY MANAGEMENT IN THE SEMICONDUCTOR INDUSTRY: CHALLENGES AND STRATEGIES
The semiconductor industry is one of the most innovative and technologically demanding sectors in the world. From the manufacture of powerful processors to microchips for everyday devices, semiconductor products characterise the modern world. In view of the extreme precision and high quality requirements, quality management (QM) plays a central role in the semiconductor industry.
SPECIAL REQUIREMENTS FOR QM IN THE SEMICONDUCTOR INDUSTRY
The semiconductor industry places unique demands on quality management. Some of the most important factors are
- High-precision manufacturing processes: The production of semiconductors takes place at nanoscale levels where the smallest deviations can affect the functionality of the product. This requires exact process controls and extensive testing procedures.
- Strict cleanliness standards: Production takes place in clean rooms, as even the smallest impurities (e.g. dust particles or chemical residues) can cause defects. This necessitates precise environmental and risk management.
- Long and complex supply chains: From raw materials such as silicon to speciality chemicals and cutting-edge production materials, every step in the supply chain must be carefully controlled in order to avoid any loss of quality.
- Short innovation cycles: The semiconductor industry is characterised by rapid technological progress. This requires quality management systems that are not only robust but also flexible in order to be able to integrate new technologies quickly.
CORE PRINCIPLES AND METHODS OF QUALITY MANAGEMENT IN THE SEMICONDUCTOR INDUSTRY
QM in the semiconductor industry is based on international standards such as ISO 9001 and industry-specific standards such as IATF 16949 (for the automotive industry). The key methods include
STATISTICAL PROCESS CONTROL (SPC)
Continuously monitoring and analysing process data helps to detect and correct deviations at an early stage.
FAILURE MODE AND EFFECTS ANALYSIS (FMEA)
This method is used to systematically identify potential errors and develop preventive measures.
SIX SIGMA
This method strives for virtually error-free production (max. 3.4 errors per million operations) and is particularly widespread in the semiconductor industry.
TOTAL QUALITY MANAGEMENT (TQM)
A holistic approach that integrates quality in all areas of the company, from product development to customer service.
CHALLENGES IN THE QM OF THE SEMICONDUCTOR INDUSTRY
The semiconductor industry is facing several challenges that affect QM:
- Miniaturisation: ever smaller chip structures (e.g. under 5 nm) increase the complexity of production and therefore also the requirements for testing and inspection systems.
- Sustainability: The pressure to work in a more environmentally friendly way is increasing. QM systems must therefore also incorporate sustainability goals, such as the use of energy-efficient production methods.
- Geopolitical risks: Conflicts and trade barriers can disrupt supply chains. A flexible and robust QM system is crucial to minimise quality risks in such situations.
- Cybersecurity: As production facilities are increasingly digitalised and networked, QM systems must also take IT security measures into account to prevent production downtime due to cyberattacks.
OUTLOOK: THE FUTURE OF QUALITY MANAGEMENT
The integration of new technologies such as artificial intelligence (AI) and big data analytics is revolutionising quality management in the semiconductor industry. Real-time data analyses allow anomalies to be detected and rectified at an early stage. In addition, digital twins enable the simulation of production processes in order to optimise quality and efficiency.
In the long term, automation and digitalisation will continue to gain in importance. Companies that rely on innovative QM approaches will be in a better position to meet increasing requirements and hold their own in a highly competitive market.
PeRoBa Quality Management from Munich - Individual Quality Management for the semiconductor industry
Consulting, implementation, audits and QM tools from a single source
PeRoBa GmbH Munich is a service provider with many years of experience for quality management especially in automotive
and mechanical engineering. We help with all important standards (VDA6.3, IATF 16949,...) on the way to certification or
re-certification. We also work closely with universities and research institutes. Managing Director Dr. Scherb teaches as a
lecturer, for example, at the Hamburger Fern-Hochschule, the FOM in Munich and is also a speaker at the TÜV-Süd Akademie,
the Bildungswerk der Bayerischen Wirtschaft and many other institutions.
We look forward to hearing from you. The best way to reach us is by phone at the number
+49 8106 / 230 89 92
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