Legacy Tool Management: Extending the Lifespan of Semiconductor Legacy Equipment

In the fast-paced semiconductor industry, legacy tools continue to play a crucial role in sustaining the global supply chain, particularly for mature nodes ranging from 180nm to 45nm. These technologies remain essential for producing chips used in consumer electronics, automotive applications, and IoT devices, where cost-effectiveness and reliability are prioritized over cutting-edge innovations.

Understanding the Legacy Technology Market

The market for legacy nodes is substantial, estimated to exceed $50 billion, driven by high demand in industrial, automotive, and smart device applications. As the industry expands, manufacturers are focusing on extending the lifespan and optimizing the performance of legacy tools to meet growing customer demands.

Benefits of Extending Legacy Tool Lifespan

Extending the life of legacy tools offers several key advantages for semiconductor manufacturers:

Cost Savings

By optimizing existing tools, fabs can avoid large capital expenditures on new equipment.

Operational Continuity

Ensures uninterrupted production for mature nodes that remain in high demand.

Sustainability

Reduces e-waste by prolonging the lifecycle of tools.

Challenges in Legacy Tool Management

One of the primary challenges in managing legacy tools is the obsolescence of spare parts, particularly electronic components. With a typical lifespan of around five years for many electronic components, fabs operating legacy tools face significant hurdles in sourcing replacement parts. This issue is compounded as OEMs shift their focus to advanced technologies, making it increasingly difficult to find parts for outdated equipment.

Maintaining a robust supply chain for legacy tools requires constant monitoring, proactive planning, and strong partnerships with OEMs and third-party suppliers. Without a reliable supply chain, fabs risk operational downtime, which can impact production schedules and revenue.

Orbit & Skyline’s Investment in Legacy Tool Management

To address these challenges, Orbit & Skyline has made significant investments in supporting legacy tool management. The cornerstone of this investment is the Orbit & Skyline Center of Excellence, a state-of-the-art facility designed specifically to tackle the unique challenges of legacy tools.

The Orbit & Skyline Advantage

Orbit & Skyline offers a unique combination of fab experts, OEM experts, and a semiconductor supply chain team. With over 15 years of experience and a global team of more than 500 engineers, the company provides end-to-end solutions for legacy tool management

Key capabilities include:

• Managing over 3,000 tools globally across etch, deposition, and clean processes
• Ensuring spare part continuity through strong OEM partnerships
• Delivering innovative, tailored solutions
• Offering a robust supply chain strategy to mitigate obsolescence risks

TSMC's Mature Fab Success

TSMC's success with mature fab operations demonstrates the importance of legacy tools. While known for its advanced nodes, TSMC’s mature node fabs contribute significantly to its revenue. By optimizing legacy tool performance and aligning with customer demand, TSMC has created a roadmap for sustained growth in mature node production.

Conclusion

As the semiconductor industry continues to grow, legacy tools remain crucial for enabling cost-effective and sustainable production. Orbit & Skyline’s comprehensive solutions empower fabs to extend tool lifespans, optimize operations, and maintain competitiveness in a demanding market.

With its extensive expertise, state-of-the-art facilities, global network, and proven track record of supporting major OEMs, Orbit & Skyline positions itself as a trusted partner for semiconductor fabs worldwide, helping to transform legacy tools into assets for growth and success.