Inside the Fab, at Scale Inside the Fab, at Scale

Inside the Fab, at Scale

Overview

Fab Operations, Delivered as an Engineering Discipline

Description

Fabs and OSATs run on a simple, unforgiving arithmetic: uptime, yield, cycle time and cost per wafer. Moving any of them in the right direction takes people who have stood at the tool—engineers fluent in equipment maintenance, process engineering, MES ecosystems and cleanroom operations, deployed in models with real accountability.

We deliver fab engineering programs inside client environments across the US, Taiwan, India and beyond from equipment install and qualification at greenfield fabs to KPI-led managed operations covering thousands of tools. We span the full domain—wafer fabrication front-end processes, ATMP and back-end, test engineering and the digital layer of MES, automation and analytics that ties a modern fab together.

97%

Equipment uptime achieved across fab operations

1,380+

Tools under management

7

Fabs and cleanrooms operated for a single client program

110+

Engineers deployed in cleanroom and fabrication environments on a single engagement

10+

Global MES deployments

Capabilities

From Tool Install to Autonomous Factory

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Equipment install, de-install, relocation and upgrades, along with preventive and corrective maintenance, calibration, troubleshooting, process sustaining and qualification across deposition, etch, lithography, metrology and back-end environments.

KPI - and SLA-led operating models covering equipment operations, process monitoring, manufacturing engineering, cleanroom operations, inventory and spares management—with governance, tracking and continuous improvement built in.

Software maintenance, obsolescence management, OS migration, feature enhancement and backporting, PCB repair and refurbishment, field support contracts and escalation.

Test program development and conversion, DIB and probe card design, test optimization, characterization and production support.

Smart factory advisory (plant assessment, solution blueprint, MES platform selection), MES/MOM, SCADA and historian implementation, lab automation (LIMS/CDS/SDMS), IT-OT integration, vision-based inspection, manufacturing analytics and digital twin, plus run-and-maintain for shop floor applications.

Process, metrology, materials and industrial engineering for R&D and pilot environments — recipe development, advanced characterization, MES administration, lab supervision and documentation control.

Fab-ready engineer development through semiconductor COEs, AR/VR-based training and AI-powered knowledge management — SME knowledge codification, vision-based task capture and RAG-based search assistants that retain what experienced engineers know.

Key Differentiators

Accelerators

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Plant-in-a-Box

pre-configured MES rollout framework delivering 30% reduction in time and effort for multi-plant deployments

MES Test Automation

40%+ reduction in regression testing effort

M360 Solution

real-time manufacturing insights for plant productivity and quality

Machine Integration Framework

accelerated equipment connectivity and IT-OT integration

InsightX

AI-led predictive maintenance for critical fab equipment, with SymphonyAI

Labs and Infrastructure

Manufacturing Infrastructure with Skin in the Game

  • Advanced Semiconductor Lab — post-silicon validation, qualification and failure analysis supporting NPI and yield stabilization
  • 25,000+ sq. ft. Class 10K ATE cleanroom with tri-temp wafer probers and package handlers
  • Cleanroom and equipment labs supporting maintenance training and process development
Section CTA
Semiconductor Fab and Manufacturing

Let's Raise Your Fab's Numbers

Talk to Our Fab Team

ERS Semiconductor Engineering Service Semiconductor Fab and Manufacturing