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Semiconductor manufacturing is by far one of the most complex technological processes. Chip fabrication facilities are expensive and expansive facilities which require round the clock water and power with a seamless supply chain of materials. These materials which essentially consist of high-grade chemicals, gases and minerals require to be transported to these facilities in stringent timelines which is not only challenging but critical. Ipso facto, these facilities present a huge carbon footprint in addition to the hazardous waste which requires disposal, besides emissions of toxic chemicals and gases. The processes of this long operational cycle are both manpower and machine intensive with a very low, in fact negligible downtime for both.
The wafer (as it is generally referred to) production has hundreds of processes till the final product stage which is time intensive, sometimes transcending different geographies.
The two focus areas which encompass this segment of manufacturing for the future are ‘Policy’ and ‘Processes’. In terms of ‘Policy’, with establishment of Indian Semiconductor Mission, available expertise of significant Indian tech leaders engaged in these activities abroad and the present requirement, a myriad of these aspects need be intricately woven into the extant and futuristic policies.
These policies could cater to incentives for innovation, R&D, manufacturing of semiconductor grade chemicals indigenously as well as specialized logistics, integral to the value chain as part of ISM 2.0, as and when approved by the government.
In terms of ‘processes’, this distinct space can be covered with implementation of new and emerging technologies in multiple segments. In terms of energy requirements, renewable energy needs to be incorporated in these processes. In terms of solar energy and wind power energy in the Indian context, India ranks fourth in the world with installed capacities of 60.81 GWAC and 40 GW respectively and installed power installation targets achieved much ahead of schedule, besides domain expertise.
This could improve efficiency and storage of power to accrue a smaller carbon footprint in these facilities. The renewable energy sector has a huge potential of scaling up and needs to be configured in conjunction with establishment of semiconductor fabrication facilities in the future.
Chip manufacturing process is arduous and time intensive with process management is an all-important facet of any fabrication facility. An increased usage of Artificial Intelligence (AI), Internet of Things (IoT) and robotics in faster and seamless process management would need to be incorporated to shorten these current manufacturing processes.
Building responsible supply chains for manufacturing processes with responsive logistics and a large indigenous content to tide over any natural or geopolitical disruptions will be pivotal as well. This would involve many things to include port handling capacities and associated training, building cryogenic containers, high end storage facilities for chemicals and gases, innovative disposal norms etc. Emission parameters of toxic gases is another challenge which can be tackled by decreasing power consumption metrics and utilization of greener gases.
Semiconductor cleanrooms are the most demanding clean rooms in the world with precise humidity and temperature requirements to prevent electrostatic discharge and limiting particle count. They not only form part of the critical infrastructure dynamics but will also necessitate homegrown expertise in the future.
While there is a renewed emphasis on critical minerals and materials including some countries alleging usage of “conflict minerals” by some big tech giants, the quest for greener materials will need to be undertaken. While this endeavor would be cost intensive and time consuming, it will have the potential to de-risk the present hegemony due to their availability metrics. Incentives for research in greener materials and adoption would be a critical piece in this jigsaw for chip manufacturing of the future.
Semiconductor manufacturing uses an estimated 264 billion gallons of water every year and requires “Ultra-Pure Water” to ensure quality and reliability of chips and processors. Water quality, its purification, incorporating recycling techniques and waste water management with high ammonia content will be the four important edifices in manufacturing processes of the future. It is therefore imperative that this aspect assumes primacy in the context of environment and future best practices.
Interestingly, the bulk of wafer fabrication facilities in the world were made operational in the mid or late 1990s and in the initial eight years of the current century. This underlines the fact that they were perhaps not built with the sustainability quotient as the prime focus. As India embarks on this journey to create these capital intensive, high technology, large carbon footprint intensive fabrication facilities, it can show the world the very viability of manufacturing critical technology, responsibly.
Shaping the semiconductor ecosystem of the future will therefore be an onerous task which will require a multi vector push of inter ministerial policy making, infusion of a large capital for creation of scientific capacities and a commitment from the industry.
Only through steps to include making our own standard operating procedures, collaborating with industry and regional players, offering financial incentives and cultivating a culture of research and innovation, can India sculpt a semiconductor landscape that empowers it to ascend as a global frontrunner. India’s role in shaping the semiconductor-driven digital future will require renewed focus in myriad aspects as we build our facilities of and for the future.
(The author is a former colonel and a policy specialist in Semiconductors and Critical Electronics; Views are personal)
