TSMC Unveils ‘Global Gigafab’ Program, Provides Glimpse into Revolutionary Process Replication

TSMC recently shared details about its Global Gigafab Manufacturing program at its European Technology Symposium. This program aims to replicate TSMC’s manufacturing processes across its various gigafab sites, allowing for efficient scaling and increased throughput.

The need for large-scale multinational fabs to have a replicable process in place has been well-documented. As chip makers expand their gigafabs, they must quickly transfer new and updated manufacturing processes to other facilities to avoid bottlenecks and maintain necessary throughput. Intel has its Copy Exactly program, which enables the sharing of process recipes across its fabs worldwide. TSMC, as it builds additional capacity in different regions, requires a similar program to maximize yields and productivity at its new fabs in Japan and the U.S. However, TSMC’s program goes beyond Intel’s, with a focus on sustainability and social responsibility.

Y.L. Wang, Vice President of Fab Operations at TSMC, described the Global Gigafab manufacturing program as a powerful global manufacturing and management platform. It ensures consistent operational efficiency and production quality on a global scale. TSMC also emphasizes sustainability, covering green manufacturing, global talent development, supply chain localization, and social responsibility.

TSMC utilizes continuous process improvements (CPI) and statistical process control (SPC) to enhance process technology. These mechanisms improve yields and reduce performance variations. The company employs machine learning-based process control, constant quality measuring, and various productivity-enhancing methods. With the Global Gigafab Manufacturing program, TSMC can share knowledge between different sites to improve yields and performance on a global scale.

Kevin Zhang, Senior Vice President of Business Development and Overseas Operations Office at TSMC, explained that when TSMC transfers technology from Taiwan to other locations like Arizona, the fab setup and process control system are replicated exactly. This ensures consistency and allows for efficient knowledge transfer.

While TSMC’s fabs in Germany, Japan, and the United States have yet to start chip production, the Global Gigafab Manufacturing program is expected to expedite the process of reaching Taiwanese levels of yields at these new facilities. With this program in place, TSMC is well-positioned for success in the coming years.

Background Information

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About Intel: Intel Corporation, a global technology leader, is renowned for its semiconductor innovations that power computing and communication devices worldwide. As a pioneer in microprocessor technology, Intel has left an indelible mark on the evolution of computing with its processors that drive everything from PCs to data centers and beyond. With a history of groundbreaking advancements, Intel's relentless pursuit of innovation continues to shape the digital landscape, offering solutions that empower businesses and individuals to achieve new levels of productivity and connectivity.

  

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About TSMC: TSMC, or Taiwan Semiconductor Manufacturing Company, is a semiconductor foundry based in Taiwan. Established in 1987, TSMC is a prominent player in the global semiconductor industry, specializing in the manufacturing of semiconductor wafers for a wide range of clients, including technology companies and chip designers. The company is known for its cutting-edge semiconductor fabrication processes and plays a critical role in advancing semiconductor technology worldwide.