As semiconductor manufacturing becomes more complex, there is an increasing demand for custom solutions to special applications. Standard systems often can&#;t take into account the combination of multiple steps required to produce an etched silicon wafer. Instead they end up creating inefficiencies with poor quality output. Custom solutions can consider each separate requirement and can assemble a production line in which each step is optimized for peak performance. Wet bench manufacturers best situated to satisfy the need for customization are those with in house expertise and those that manufacture the bulk of their equipment themselves.
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In House Expertise Leads to Optimized Custom Designs
When a company has extensive experience as a wet bench manufacturer, it can evaluate special application requirements, identify key features that will be needed and use its expertise to design the corresponding equipment. The etching and cleaning processes to be used, the concentrations of chemicals, the timing of steps and the use of automation all impact the design of individual elements and of the complete production line. Companies that have designed many such systems will immediately know what design parameters are appropriate and proceed to the details of the customization.
A company has typically acquired its in house expertise by designing many different systems and gaining experience with the features included in each one. The design experience and data gained from testing and from customer feedback allow the company to design an optimized system without going through a trial and error phase. The result is a design based on real wet process results and one that can be built and put into operation without extensive corrections and modifications.
Custom Manufacturing Requires In-House Capabilities
Once a custom design is in place, the corresponding equipment has to be built. The complete customization process is extremely efficient when design and manufacturing take place within the same company. The supplier with in-house expertise in both design and manufacturing of wet bench equipment can use manufacturing experience to produce a low cost and easily constructed design. The company can then build the equipment to perform exactly as needed.
In house manufacturing means the company has experience with materials, knows the limitations of manufacturing processes and is aware of the capabilities of tools and equipment. Based on experience with equipment that has gone into production, a company with in house design and manufacturing expertise can offer custom solutions that really work.
In House Design and Manufacturing Leads to Effective Customer Support
Wet bench manufacturers that design and build their own equipment can provide customer support and service that quickly answers questions and solves problems. Engineers and technicians that have worked on the equipment and are familiar with it won&#;t have to check with third party suppliers and will be able to propose effective solutions. Companies with such in-house expertise can not only prioritize excellent customer support but can also deliver concrete results.
Modutek Has In House Design and Production Expertise
Modutek&#;s personnel design and build all their own equipment including design and programming of automation software. The company&#;s in house expertise and production know-how includes design, assembly and testing of all wet bench equipment supporting both acid and solvent applications. While the company has a complete line of standard equipment and systems, it&#;s in house capabilities allow it to offer customized solutions for any special applications.
Modutek has technicians and engineers familiar with electrical schematics, plumbing diagrams and software documentation. Company programmers write the automation software for semi-automatic and fully automated wet bench stations. Modutek&#;s in house expertise allows the company to provide the best possible designs, equipment and customer support.
1. Can You Build My Spec?
This might seem like a no-brainer, but a detailed spec sheet is the first and most important step in ordering the right equipment and finding a manufacturer. When your manufacturer knows your production volume, materials, process requirements, electrical needs and other requirements, they can build a system that fits seamlessly into your facility. The more specific your spec sheet, the more accurate the build. For this reason, one of the first questions to ask your equipment manufacturer is whether or not they can build the spec for you.
Make sure your spec sheet includes following:
Production amount
Electrical rating
Environmental hazards (combustible dust, extreme heat, moisture etc.)
Material hazards (caustic materials, respirable dust hazards etc.)
Build material requirements (stainless steel, food grade, polyethylene etc.)
Sanitation regulations
Safety requirements
Upstream and downstream system operations
2. Do You Have Any Questions?
It&#;s essential to ask your manufacturer the right questions, but it&#;s also important to address their questions as well. If the manufacturer doesn&#;t ask for any clarification about your spec or requirements, this might be cause for concern. Be wary of too many easy answers; make sure your manufacturer thinks about your constraints or potential obstacles as hard as you do.
3. Are All Specifications In The Quote?
From the small details to the big-ticket items, all of your specifications should be written in the quote. If it&#;s not written down, miscommunications between sales and manufacturing can happen and you get might not be what you thought. There are just as many important questions to ask manufacturers about the quote as there are about the build itself.
4. Is This Quote Accurate?
A lower price is tempting, but low-ball offers tend to pile on extra costs and frustration later on. Make sure you know the right questions to ask manufacturers about the price; how accurate is it? What could cause it to change? Are testing, delivery, and maintenance included? When comparing quotes, make sure all the same considerations are included on each.
5. What Components Do You Use?
If you, your technicians, manager, or client prefer certain brands of controls or other manufacturer components, ask if these are available. Make sure your manufacturer uses off-the-shelf components; specialized equipment can make later maintenance, upgrades, and repairs much harder and more expensive.
6. Who Can I Call About This System?
One of the best questions to ask manufacturers about your system is, who else uses it? Your manufacturer should be able to provide references you can talk to. When checking these references, make sure the system and process is the same. Remember that differences in the process, additional parts, or a system purchased more than five years ago might not be the same.
In addition to information about the system, the reference can also tell you about the manufacturer. Consider the following questions for your reference:
7. What Testing Do You Provide?
Testing is the best way to make sure that your system integrates properly and completes the process without a problem. Factory approval testing should be available before shipping. The manufacturer should also be able to conduct ingredient testing to address any potential problems with bulk density, angle of repose, particle size, materials hazards, and more.
Make sure you know the right questions to ask your manufacturer about equipment testing; when have they conducted this testing before? How much does testing cost? Is it written into the quote?
8. Are You Certified?
It&#;s better to double-check that your manufacturer has required certifications and adheres to standards rather than find out later your equipment might not be up to par.
Consider the following certifications and standards;
UL wiring and control standards
ASME and/or AWS welding standards and codes
ISO standards
OSHA equipment safety standards
IEEE standards
Canadian, European Union, other international standards
9. What Service Do You Offer?
Knowing the right questions to ask about the service department will make sure good service continues after purchase. Do they have an in-house service department? How many technicians are there? Do they offer set-up and training? An extra investment in an in-house, top-notch service department can prevent costly downtime later.
10. Can I Purchase Wear Parts?
The majority of your system should have a long, effective life, however some parts do inevitably wear down. Ask about sprockets, nozzles, replacement belts, screens, strainers, belt and valve calibration, etc. Addressing these concerns at purchase will reduce downtime drastically later.
11. Will This System Age Well?
Durability isn&#;t the concern when it comes to system aging. If regulations change, new technology becomes available, or ingredients change, can the system adapt? Consider potential changes on the horizon, or industry upsets you&#;ve seen in the past.
Can the system adapt to:
Stricter sanitation requirements
Stricter safety requirements
More precise measurements
Changes to ingredient mixing
Additional nutrient needs
New software capabilities
IoT integration
As the saying goes, the key to success is 90% planning and 10% execution. Once you know and verify that your manufacturer can and will build the system you need, the hardest and riskiest part of the job is done. Ask your manufacturer the right questions from the start and you can have confidence in your system when it arrives.
Having difficulty finding a manufacturer to make your product for your exact system? Contact us today to find out what we can do for you.
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