Smart Automation for Mature Nodes: Extending the Lifespan of Legacy Semiconductor Fabs

Legacy fabs - semiconductor manufacturing facilities built primarily in the 1980s and 1990s - continue to play a vital role in the global semiconductor ecosystem. These facilities typically utilize older process nodes such as 65 nm, 90 nm, or even 250 nm, and operate with wafer sizes of 200 mm or less. Unlike state-of-the-art fabs producing cutting-edge 7, 5 or even 1.8 nm chips on fully automated 300 mm wafer lines, legacy fabs often rely on manual or semi-automated workflows and equipment. Despite their age and lower technological sophistication, legacy fabs produce a significant share of chips used in industrial, automotive, and embedded applications - markets where mature technologies remain indispensable.
Over the past few decades, the semiconductor industry has experienced a significant geographic shift, moving much of its production capacity from the U.S. and Europe to Asia - primarily China, Taiwan, and South Korea - driven by economic efficiencies and investment in high-volume manufacturing. However, current geopolitical developments, supply chain vulnerabilities exposed by the COVID-19 pandemic, and a renewed emphasis on technological sovereignty have led to a partial reversal of this trend. Countries across Europe and North America are once again investing in domestic semiconductor capabilities, including legacy manufacturing.
This emerging landscape presents a timely opportunity for the "revival" or "second life" of legacy fabs. However, to remain economically viable and competitive, these fabs must undergo significant modernization, with efficiency improvements being paramount. One of the most impactful levers for transformation lies in the automation of material handling. Unlike advanced fabs equipped with automated transport systems and intelligent logistics networks from the start, many legacy fabs still depend on manual operations, which limit throughput, traceability, and reliability.
This presentation explores the specific challenges and opportunities involved in upgrading legacy fabs through material handling automation. It highlights technical strategies for retrofitting existing infrastructure, integrating automation solutions, and navigating the trade-offs between investment cost and long-term efficiency gains. Through real-world examples and best practices, the talk will demonstrate how targeted modernization can extend the life and enhance the strategic value of legacy fabs, particularly in a world where supply chain resilience and regional capacity built up are becoming increasingly critical.