Many manufacturing leaders — including those working at semiconductor fabs — have been making ambitious net-zero goals. However, these facilities are extremely resource-intensive, so those involved have significant progress left to make. Fortunately, multiple organizations have pledged their commitment to important environmental and emissions-related goals and outlined their strategies for achieving them. What possibilities exist in net-zero semiconductor manufacturing, and which are most worth people’s time?
Prioritize Sourcing Clean Energy
Many industrial operations require significant energy, but a March 2024 report identified leading semiconductor manufacturers as having particularly high demands. Additionally, the researchers asserted that those companies rely too heavily on renewable energy certificates to offset usage rather than directly installing green infrastructure at their manufacturing sites to accommodate power needs.
More specifically, the data indicated that newly constructed factories for the world’s four largest semiconductor makers use 200% the annual electricity consumption of Seattle. Another finding was that semiconductor fabrication facilities are among the most energy-intensive parts of the IT supply chain, with some chips powering devices that often account for 50% of those products’ carbon footprints.
Particular examples mentioned in the report included the four new facilities being built in Arizona by two semiconductor production leaders. These factories will collectively use the electricity typically consumed by 260,000 homes. However, those involved with their construction have yet to sign renewable power contracts to align resource usage with future net-zero targets.
The report’s authors urge semiconductor factory executives to focus on adding renewable energy to local grids. Otherwise, they warn, the construction of new manufacturing facilities will drive up demand and investment in fossil fuel-based energy sources. The researchers also advocate for leaders to align their industrial and decarbonization strategies, define clear strategies for success and collaborate with major customers.
Broaden the Types of Chips Produced
Semiconductor producers recently grappled with a persistent chip shortage characterized by numerous complicating factors. For example, the issue halted the production of approximately 18 million automobiles that used the particularly in-demand components. However, resolving the shortage was more complex than it may have seemed to industry outsiders. That is because the automotive industry uses a niche kind of chip viewed as a legacy option by many producers who use semiconductors for other reasons.
Still, semiconductor industry professionals have become well-accustomed to responding to industry surges and fluctuations that require adjusting their production methods or targets. Those interested in achieving net-zero semiconductor manufacturing may need to do so again by increasing the company resources set aside for greener chip designs.
Indeed, since the components themselves have associated carbon footprints, investigating more eco-friendly options could fit into producers’ net-zero aspirations. One initiative comes from a British University where teams are developing wide/ultra-wide bandgap compound semiconductors for high-voltage electronics. Those involved envision improved semiconductors will enable more compact and highly efficient devices that function with reduced energy loss.
Additionally, this project will allow participants to investigate options that would make current manufacturing methods more productive. When semiconductor fabrication plants can transition to strategies that result in both the manufacturing techniques and produced products being better for the environment and having fewer associated emissions, those involved will get closer to fulfilling their net-zero plans.
Practice Data-Driven Strategies for Net-Zero Semiconductor Manufacturing
Although there is no single way to reach net-zero semiconductor manufacturing goals, parties can determine where to focus their efforts by collecting production data and using it to track progress after creating resource-related baselines. One starting point is to consider what the company needs to complete each production phase and the average amount of resources consumed.
For example, many manufacturing steps require water, such as to rinse the residue from chips that could interfere with their performance if not removed. Relatedly, water is essential for keeping manufacturing systems cool and generating electricity. However, production plant leaders can install leak detection sensors and other connected technologies for better oversight.
They will then receive near-real-time data about average resource usage, the amount consumed per shift and more. Such statistics make it easier to spot the anomalies that suggest companies are using more water than usual or necessary. Additionally, decision-makers can use the production data to influence new actions or practices established to minimize water use and other vital resources.
The statistics can also be incredibly revealing and motivating for leaders who did not previously realize excessive resource use was occurring. Many people dislike change but feel compelled to adopt strategies for the greater good, especially after learning problems exist.
Similarly, smart sensors could confirm that resource overconsumption stems from surprising places that are easy to address almost immediately. Those small wins encourage people, increasing the likelihood they will put their energy toward the goals that may be more challenging to achieve but even more rewarding.
Become Aware of External Emissions Sources
People understandably pay a lot of attention to internal activities when they assess how to get closer to their net-zero milestones. However, it is also important for people to develop a deeper understanding of Scope 3 emissions — those not owned or directly controlled by the reporting organizations.
Conversely, Scope 1 emissions arise from activities within fabs, and Scope 2 emissions are those generated by heating, cooling, electricity and steam-related equipment. The main challenge of Scope 3 emissions is that they come from things that happen once products leave factories, so they are much harder for semiconductor leaders to influence. However, statistics show that Scope 1 and 2 emissions encompass just 65% of semiconductor fabs’ total greenhouse gas emissions.
That means people can only maximize their net-zero semiconductor manufacturing efforts by learning more about their Scope 3 emissions sources and exploring the most relevant possibilities for reducing them. Since many Scope 3 emissions connect to transportation-related activities in supply chains, engaging with logistics partners and getting them interested in emissions reductions will likely be necessary.
One option is to support suppliers in establishing gradual changes, such as switching their fleets to electric vehicles, changing applicable routes to make them more efficient or coaching drivers to minimize aggressive driving behaviors that can lead to more fuel consumption and tailpipe emissions.
Commit to Net-Zero Semiconductor Manufacturing
The main thing semiconductor factory leaders should remember after reading these tips is that it takes time to develop and implement net-zero plans. Additionally, success requires support from people at all organizational levels. However, making a serious commitment now is one of the most powerful things a decision-maker can do to begin establishing a framework for lasting positive changes that could inspire peers.
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