The semiconductor manufacturing industry is ever-evolving and constantly changing. The semiconductor industry outlook is predicted to increase massively in the coming years as the world continues to shift toward digitalization, automation, and Smart technologies. In the semiconductor world, remaining agile and adaptable is the key to staying competitive in this volatile, fast-growing market.
Whether semiconductor manufacturers produce wafers or equipment, staying current with new technologies and smart tools is crucial. In this article, we’ll discuss the importance of adaptability in semiconductor fabs and the different Atlas Copco Smart tools and solutions that can help.
Adaptability matters
Complex production processes can typically characterize the semiconductor manufacturing industry. Even focusing on just one specific component, such as a power box, hundreds of variations can be manufactured. Semiconductor manufacturers, their assembly lines, and their customers depend on their ability to produce these units with high precision according to the specifications of each individual unit model. There is often little to no opportunity to set up dedicated lines for single models. Instead, each assembly line must adapt to multiple models that run along the same line.
This is why properly implementing smart tools into these workstations can significantly improve the performance of assembly lines. Further, they support the adaptability requirements that allow your line to keep up with high production rates. The combination of Smart tools and advanced software solutions provides not only flexibility during the manufacturing process but also peace of mind; the process is fully controlled through clear operator guidance, complete data collection, and full process transparency.
Currently, it’s quite common to find semiconductor fab assembly lines that rely on more basic tools, such as a mechanical torque wrench, to complete complex processes. The wrenches may be getting the job done, but they aren’t necessarily the best way to complete the work. Mechanical torque wrenches are often considered entry-level tools that cannot provide operator guidance, traceability, or data collection. This opens the door to operator error, rework, and a multitude of other assembly issues.
The Tensor IxB family of integrated controller tools – semiconductor game-changers
Atlas Copco’s Tensor IxB tool family consists of two wireless nutrunners that feature integrated controllers: The Tensor ITB and the Tensor ICB. Because the tightening controller is integrated directly into the tool itself, the days of separate, physical controllers that take up space in the workstation and make for complex cable management are gone. Further, the Tensor ITB and Tensor ICB integrated controller tools are extremely advanced Smart tools designed to meet the demands of today and the future.
Tensor IxB applications in the semiconductor industry
The Tensor IxB integrated controller shares the same commonality with Atlas Copco’s next-generation Power Focus 8 controller, making the Tensor IxB family of tools ideal for multiple semiconductor equipment manufacturing applications. Take the assembly of semiconductor etching equipment as an example. Once implemented into an assembly line, these machines perform a critical job that must be executed perfectly to avoid health, safety, and environmental issues.
For a job like this, mechanical wrenches can cause ergonomic issues in operators. As stated above, they also don’t offer any data collection capabilities or provide the operator guidance needed to avoid rework and production errors. This is where the Tensor ICB integrated controller tool enters the picture. The Tensor ICB provides an optional eHMI that enables clear operator feedback. Because the tool doesn’t rely on a separate controller, the Tensor ICB contains all the data required to run on the tool.
Another application semiconductor manufacturers face is the assembly of chemical vapor deposition machines. Typically assembled using a mechanical torque wrench, this application suffers from common assembly errors, including floating or missing screws, crossed threads, and bit cam-outs. These issues can be completely avoided using a Tensor ICB integrated controller tool. This integrated controller tool allows for easy identification of tightening issues, improved angle, and torque accuracy, and significantly increased product quality.
Are you interested in learning more about how Atlas Copco can take your semiconductor fab to the next level? Contact us and schedule a demo today!