Semiconductor manufacturing is renowned for its substantial water consumption, often exerting significant pressure on local resources. The phrase "fabs are thirsty" aptly encapsulates the industry's demand for water. This presentation aims to provide a facility design perspective, addressing the challenges encountered in greenfield (new sites) and brownfield (existing sites) designs, and exploring the integration of smart manufacturing and big data. Fluor is a company committed to support the evolving needs of designing and building semiconductor facilities. The presentation will go over specific examples of water sustainability solutions implemented in design by Fluor and will cover trends and tools in industry 4.0 technologies that are not fully implemented due to the risks associated with deviations. The presentation will address challenges experienced in design including: 1. Greenfield and Brownfield Designs: Designing semiconductor manufacturing facilities, whether greenfield or brownfield, presents unique opportunities. Water sustainability solutions in greenfield projects offer flexibility in design but require substantial initial investment and planning. Brownfield projects must navigate existing infrastructure constraints while upgrading to modern standards as well to adhering to cities evolving regulations. 2. Robust and Redundant Systems: Implementing robust and redundant systems for water utilities is essential in semiconductor manufacturing facilities. Ensuring sustainability in these systems is imperative, driven not only by corporate sustainability goals but also by municipal regulations. Advanced water treatment and recycling integration are critical components of these efforts. 3. Smart Manufacturing and Big Data: The adoption of smart manufacturing and big data analytics is crucial for optimizing operations and resource management. These technologies enable real-time monitoring and predictive maintenance, enhancing efficiency and reducing downtime. However, decision-making often relies on previous experiences, which can sometimes overshadow data-driven insights. 4. Solutions: Fluor has implemented several water sustainability solutions in semiconductor facility designs. These include advanced water recycling systems, efficient wastewater treatment processes, and the use of Reclaim City Water for projects. Such measures significantly reduce freshwater consumption and mitigate environmental impacts. 5. Trends and Tools: Industry 4.0 technologies, such as IoT, AI, and digital twins, are transforming semiconductor manufacturing. These tools offer enhanced connectivity, data analytics, and automation, leading to improved productivity and resource management. Despite their potential, full implementation is often hindered by risks associated with deviations from established processes. 6. Integration with Legacy Systems: Integrating Industry 4.0 technologies with legacy systems, particularly in discrete electronic sites and AT facilities, represents a significant challenge. This integration requires substantial investment, which may be prohibitive for smaller players. Managing costs is a major challenge, as initial investments can deter companies from long-term gains in production and efficiency. 7. Call to Action: To fully embrace the new age of knowledge and technology, the semiconductor industry must prioritize sustainable practices and leverage advanced technologies. Collaboration and innovation are key to overcoming challenges and driving progress in water sustainability and smart manufacturing.
