Success Stories

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Process Simplification in Medical Device Manufacturing Boosts Production Capacity by 5x Executive Summary Scaling production in medical device manufacturing often means heavy investments in equipment, personnel, and time. But what if you could achieve exponential gains with none of that? One medical device manufacturer did exactly that — increasing production capacity fivefold through smart, strategic process simplification, not capital expenditure. The Manufacturing Challenge The company produces implantable devices made of PDMS (polydimethylsiloxane) micropillars infused with magnetic powder. These flexible pillars respond to external magnetic fields and require high-precision processing. Demand was rising, but the production capacity was limited. The conventional response was predictable: buy more equipment and hire additional staff. The...

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$20M+ in annual savings

Eliminating Plasma Etch Step Solves Yield Degradation – $20M Annual Gain Process Overview Microchip production is a complex series of material deposition and removal steps performed on silicon wafers. Toward the end of this process, metal bumps are formed to enable electrical connections between the chip, its final package, and external components. One of the last steps traditionally included a plasma etch process, used to remove a thin film of refractory metal between the bumps. This step was assumed necessary to ensure electrical isolation—until deeper analysis suggested otherwise. The Yield Degradation Challenge A recurring issue plagued the production line: the longer the delay between the plasma etch process and final wafer...

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~ $10M annually

Solving Cooling Water Acidity Issues: Preventing Corrosion in Manufacturing Plants Background A reliable cooling water system is essential to maintain the performance and longevity of manufacturing equipment. Precise control of cooling water parameters is critical for uninterrupted and efficient production. The Challenge Rising Water Acidity and Corrosion The manufacturing plant faced persistent water acidity issues impacting the effectiveness of the cooling water system. Frequent water replacements became necessary, each requiring costly and disruptive plant shutdowns, significantly affecting productivity and operational budgets. Initial Approach Previously, acidity levels were managed by adding basic chemical compounds. However, this approach inadvertently increased water conductivity, eventually necessitating water replacement anyway, perpetuating a costly cycle without...

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~ $10M annually

Preventing Silicon Wafer Breakage in the Flash Furnace Process Overview of the Flash Furnace Process in Semiconductor Manufacturing The flash furnace process is a critical step in semiconductor manufacturing, rapidly heating silicon wafers to approximately 1000°C within just one to two seconds. To prevent oxidation of previously deposited layers, wafers are processed in a nitrogen-filled chamber. Each wafer rests on a specialized quartz pedestal, featuring precise bumps and pins, and is heated using a powerful lamp located at the chamber’s apex. Challenge: Recurring Silicon Wafer Breakage Despite its efficiency, the flash furnace process faced a persistent challenge: silicon wafer breakage. Across multiple production tools, wafer breakage rates ranged between...

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~$300,000 per year per unit

Solving Furnace Contamination in Semiconductor Manufacturing The Challenge: Contamination Risk in High-Precision Manufacturing In the competitive world of semiconductor manufacturing, even a trace of furnace contamination can compromise an entire batch of wafers. This case involved repeated issues of contamination during one of the thermal processing stages — a crucial step where consistency is vital for yield and quality. Each occurrence of furnace contamination led to wafer loss, equipment downtime, and productivity decline. As the problem escalated, it became clear that conventional approaches were not enough to protect production integrity. The Conventional Approach: Cleaning, Monitoring, and Repeating The standard response was to intensify maintenance routines and...