Automation solutions in semiconductor and electronics manufacturing- Image: Xpert.digital
From cost pressure to the competitive advantage: automation as a gamuchanger in chip production
Automation solutions in semiconductor and electronics production
The semiconductor and electronics industry goes through a technological revolution that is powered by advanced automation solutions. This development is of crucial importance because the requirements for precision, efficiency and product quality increase steadily while the costs have to be reduced at the same time. With the ongoing AI boom and the increasing demand for high-performance semiconductors, automation becomes a strategic imperative for the entire industry.
Current market development and trends
Growth forecast for 2025
The semiconductor industry faces an extraordinary growth year. For 2025, market researchers predict growth of over 15 percent, driven by the increasing demand for artificial intelligence and high performance computing. The global semiconductor market is to reach a volume of $ 716.7 billion in 2025, which corresponds to an increase of 13.8 percent compared to 2024.
The planned expansion of the production capacities is particularly noteworthy: 18 new semiconductor factories should start building in 2025, with most of them going into operation between 2026 and 2027. These investments underline the central role of automation when coping with increasing demand.
Technological drivers
The relevant driver for this development is artificial intelligence. Hyperscales invest billions of US dollars in the development of complex AI algorithms, which in particular increases the demand for GPUS and High-Bandwidth Memory (HBM). The HBM turnover is expected to increase by 284 percent to $ 12.3 billion in 2024.
Core areas of automation in semiconductor production
Wafer handling and robotics
The precise handling of silicon-wafers is one of the most critical tasks in semiconductor production. Modern wafer handling robots must safely transport extremely thin silicon discs with up to 40 micrometers thickness and diameters of 150 to 300 millimeters. These high-fragile materials go through up to 1,200 process steps and often have the value of a mid-range car per cassette.
The robotic solutions for wafer handling are characterized by the following properties:
- Vacuum-based gripping systems for contamination-free handling
- High -precision positioning with accuracy in the micrometer range
- Pure space compatibility up to ISO 7 standards
- Integration into existing production lines of various machine manufacturers
Automated test systems (ATE)
Automated test systems form the backbone of quality assurance in semiconductor production. These systems enable tests with high throughput rate and ensure the early detection of errors, which improves product quality and ensures that strict industrial standards are observed.
ATE systems are used in different phases of semiconductor production:
- Design verification
- Production tests
- Error analysis
- Industry-specific tests for automotive, aerospace as well as the defense industry
Cleaning machine automation
Automation in clean rooms requires specialized solutions that meet the highest cleanliness standards. Modern systems such as the Smart Semicon Fabrication systems offer high-precision automation for the entire wafer production of polishing processes to packaging.
Key features of clean room automation:
- Camera -based positioning systems for automatic wafer recognition
- Fast cycle times for maximum efficiency
- ISO 7 standard conformity
- Flexible adaptation to different wafer sizes (150-300 mm)
Automation in electronics production
SMT lines and pick-and-place technology
Surface Mount Technology (SMT) lines are at the center of modern electronics production. The automation of these production lines includes high-precision pick-and-place systems, which place microscopic components on circuit boards. Computer vision systems enable precise positioning and significantly reduce human errors.
Modern SMT automation integrated:
- 3D SPI and AOI systems with AI support
- Vego handling series for reliable material flow
- Laser markers for traceability
- Precision printer with multiclamp technology
Quality control and inspection
The automatic optical inspection (AOI) is revolutionized by machine learning. New procedures significantly reduce the pseudo -fold rate and minimize manual follow -up checks. The integration of AI algorithms enables a robust distinction between pseudo and real errors.
Offer advanced inspection systems:
- 3D image recording by strip projection technology
- Measurement of paste heights from 20 µm to 150 µm
- Detection of particles, notches and holes
- Speed -optimized camera heads
Reflow control and process automation
The precise control of reflow stoves is crucial for the quality of solved connections. Modern reflow controllers automatically monitor and control complex temperature profiles in order to achieve optimal soldering results. These systems can save up to five different parameter sets and automatically switch between different soldering profiles.
Collaborative robotics (cobots) in electronics production
Areas of application and advantages
Collaborative robots have established themselves in electronics production. They enable safe cooperation between humans and machines without expensive protective devices. In the electronics industry, cobots take on precisely assembly and soldering work as well as product tests and quality controls.
Typical cobot applications:
- Chip test with vacuum vacuums
- Touch screen device tests
- Soldering circuit boards
- Automated function tests
- Assembly and packaging processes
Success examples from practice
At Siemens in Erlangen, more than 70 cobots automate different manufacturing processes. Frank Elektronik was able to double its production capacity by using Cobots, from 430-450 to over 800 devices per shift. These examples demonstrate the considerable potential of collaborative robotics for increases in efficiency.
Predictive maintenance and condition monitoring
Condition monitoring in critical applications
Predictive maintenance is becoming the key factor for minimizing unplanned system standstill sites. In the semiconductor production, downtime costs in the median can be over 100,000 euros per hour. Modern IoT solutions use acoustic sensors and machine learning algorithms for early damage detection.
Include innovative approaches:
- Acoustic Analyzer for Overhead Vehicles (OHV)
- Driving noise analysis for disruptive factor detection
- Edge-Ki for continuous state monitoring
- Visualized dashboards for technicians
IoT sensors and data acquisition
IoT sensors play a central role in modern automation. LPWAN, BLE, NFC and WLAN sensors enable the recording of precise real-time data for different applications. In clean rooms, specialized sensors are used for monitoring particles, temperature, moisture and air pressure.
Industry 4.0 and digital transformation
Intelligent factories of the future
The Bosch semiconductor plant in Dresden is considered a pioneer for Industry 4.0 and demonstrates the future of chipfearing. The highly automated, fully networked factory combines methods of artificial intelligence with integrated processes and self -optimizing systems.
Core characteristics of intelligent semiconductor factories:
- Data -controlled, self -optimizing processes
- Complete networking of all production steps
- AI-based optimization of wafer production
- Six weeks throughout the raw wafer to the finished microchip
Manufacturing Execution Systems (MES)
MES systems form the bridge between the ERP systems and the production level. They enable real -time monitoring and control of production processes, including resource planning, order processing and quality management. The integration of MES systems promotes the seamless flow of information between different departments.
Cybersecurity in networked production
The increasing networking also has significant cybersecurity challenges. Networked automation systems are exposed to an increased risk of cyber attacks that can cause significant damage to production systems.
Critical security measures include:
- Regular system updates
- Network segmentation for containing attacks
- Secure authentication and authorization
- Employee training for cybersecurity-Auwareness
Autonomous robots conquer clean rooms and digital twins shorten development cycles drastically
Machine learning and AI integration
Machine learning revolutionizes the defect in wafer production. Convolutional Neural Networks (CNN) and Wavelet Scattering Transformation (WST) models already achieve accuracy of 96-97 percent in automated defect detection. These technologies enable more precise quality control in reduced manual interventions.
Digital twins
Digital twins are established as powerful tools for optimizing manufacturing processes. They enable the virtual simulation of complex systems without physical prototypes, which significantly shortens development cycles and reduces costs. In electronics development, digital twins can optimize the entire life cycle from components to complete production streets.
Mobile automation
Autonomous guided vehicles (AGV) and mobile robot revolutionize transportation in clean rooms. Systems such as the Hero FAB AGV combine established robot technology with innovative vehicle concepts for fully automatic transport between process tools. These solutions offer 24/7 operation with high payloads of 100-150 kg.
From manufacturing to the smart factory: Why automation decides on success
Automation in semiconductor and electronics production is in a phase of rapid development. Driven by AI demand and technological innovation, production systems develop into highly networked, self-optimizing systems. The successful integration of robotics, AI, IoT and predictive maintenance will be crucial for the competitiveness of companies.
While the industry is heading for record growth, manufacturers must also manage challenges such as cybersecurity, shortage of skilled workers and increasing complexity. The companies that invest in advanced automation solutions today will be the winners of tomorrow and significantly shape the future of electronics production.
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