safety critical: driving quality and supply smc presentation_tcm1… · system security system...
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Safety Critical: Driving Quality and Supply Chain Requirements for Automotive Electronics
Dr. Anish Tolia, VP of Global Marketing, Linde ElectronicsSeptember 20, 2017
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Safety Critical
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Hyundai
Volkswagen
General Motors
FordBosch
Tesla
BMWDelphi
HondaToyotaMercedes Benz
NissanContinental
ElektrobitDenso
Tesla
Driven by innovation and growing regulation
Automobile industry co-locating with semiconductor industry to accelerate innovation
In Europe, countries sunsetting the internal combustion engine
Technology company Automotive company
Apple
Uber
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Electronics ubiquitous on cars
Automaticbraking
Adaptive cruisecontrol
Adaptive frontlighting
Airbagdeployment
Enginecontrol
Parentalcontrols
Instrumentcluster
Nightvision
Head-updisplay
Driveralertnessmonitoring
Windshieldwipercontrol
Eventdata recorder
Auto-dimmingmirror
Accidentrecorder
Interiorlighting
Active cabinnoise suppression
Voice / datacommunications
Cabin environment controls
DSRC
Entertainmentsystem
Battery management
Lanecorrection
Electronic toll collection
Digitalturn signals
Navigation system
Securitysystem
Active exhaustnoise suppression
Activesuspension
Hill-holdcontrol
Regenerativebraking
Antilockbraking
Tire pressuremonitoring
Parking system
Electronic stabilitycontrol
Seat positioncontrol
Transmissioncontrol
Lane departurewarning
Blindspotdetection
Remotekeyless entry
OBDII
Activevibration control
Cylinderde-activation
Idle stop / start
Electronicvalve timing
Electronicthrottle control
Electricpower steering
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Electronics ubiquitous on carsSafety Negligible
Entertainmentsystem
Electronic toll collection
Remotekeyless entry
Instrumentcluster
Head-updisplay
Cylinderde-activation
Idle stop / start
Auto-dimmingmirror
Interiorlighting
Active cabinnoise suppression
Voice / datacommunications
Cabin environment controls
Seat positioncontrol
Navigation system
Battery management
Parentalcontrols
Electronicvalve timing
Regenerativebraking
Activevibration control
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Electronics ubiquitous on carsSafety Enhancement
Tire pressuremonitoring
Nightvision
Windshieldwipercontrol
Eventdata recorder
OBDII
Digitalturn signals
Hill-holdcontrol
Parking system
Adaptive frontlighting
Driveralertnessmonitoring
Accidentrecorder
Lanecorrection
Lane departurewarning
Securitysystem
Activesuspension
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Automaticbraking
Airbagdeployment
Enginecontrol
Electricpower steering
Electronics ubiquitous on carsSafety Critical
Electronicthrottle control
Blindspotdetection
Electronic stabilitycontrol
Transmissioncontrol
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Now becoming computers on wheels
Cameras~20-40 MBper second
Radar~10-100 KBper second
Sonar~10-100 KBper second
GPS~50 KB
per second
Lidar~10 -70 MBper second4,000 GB
per day…each day
Autonomous Vehicles
Source for data: Intel
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Planes rely on chips for safety –achieved by redundancy
Jets manufacturedper year
< 2000
Base price
$270 million
Passenger vehicles manufactured per year
100 million
Base price
$27,000
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A fast growing market
4.0%
4.2%
5.5%
5.7%
6.4%
9.1%
14.1%
Consumer
Gov/Mil
Comm
Computer
Total ICs
Ind/Med
AutomotiveMarket representing around $35B in 2016
Growing much faster than the total IC market
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Automobile application will grow all areas of semiconductor design and fabrication
If all cars have the same level of intensity of i3, this represents
600k wspm capacity requirement
Note: This car has no autonomous driving capability.
CMOS 53%
Example of semiconductor content in a BMW i3 (based on silicon area)
Source: Applied Materials, TechInsights
CIS 3%
Analog 9%
MEMS 3%
Memory 14%
Power 18%
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5 to 10 years
2 to 5 years
10 to 70
Environment
<<1%
- °C
2 to 5 years
Average 1 year
0 to 40
Low
<10%
C°
Up to 15 years
Up to 30 years
40 to 160
0% to 100%
Target: 0% failure
Requirements for cars are higher than for phones
Increased requirementsLifetimeSupplyOperating conditions
Lead to “Zero defect” policyTraceability
Consumer Industrial Automotive
Operation time
Supply
Temperature - °C
Humidity
Tolerated failure rate
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Quality: Between raw materials and the cleanroom
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Mass market safety only achievable with quality across the full supply chainMaterial providers like Linde are the quality gatekeepers
Raw materials
Chemical production Purification Blending Analysis Distribution
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Between the variability of the raw material source…
Fluorspar mine: HF, NF3, SF6, CF4, etc.
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Between the variability of the raw material source…
Tungsten mine: WF6, WCl5
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Between the variability of the raw material source…
Germanium mine: GeH4, Ge2H6
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…and the precision of manufacturing
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…and the precision of manufacturing
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Material suppliers like Linde are the quality gatekeepers
Source Quality Use
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Spec
0 10 20 30 40 50
ppm impurities
Number of measurements
Quality: Customers are driving tighter requirements
CustomersExpect Linde to meet purity specifications and control limits
ExampleSpecification: 50 ppmControl limit: 20 ppmMean: 8 ppm
Mean
+3σ
Are even more concerned about unknown and uncontrolled impurities
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Managing supply chain determines quality
Measure at each step, prevent defects, continuous improvement
Measurement systems analysis (MSA), Statistical process/Quality control (SPC/SQC)
Rec
eiving
Prep
Purificatio
n
Blending
Fill
Traditional quality focus
QA
/QC
/Lab
Delivery
Raw materials Final product quality
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Production plant for Electronic Specialty Gases: Cylinder preparation
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Production plant for Electronic Specialty Gases: Cylinder filling
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Production plant for Electronic Specialty Gases: Blending
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Production plant for Electronic Specialty Gases: Analysis
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Supply chain: Ensuring business continuity
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Supply interruptions can be caused by natural disastersFukushima Earthquake and Tsunami: 2011
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Supply interruptions can be caused by human eventsBeijing Olympics: 2008
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Supply interruptions can be caused by human eventsG20 Summit: 2016
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Supply interruptions can be caused by human eventsTianjin Port Explosion: 2015
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Loma Prieta Earthquake: 1989
And they can happen close to home
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And they can happen close to homeHurricane Harvey: 2017
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Linde global suppliers network: multiple sourcing HCl
Global EM supply network
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Linde global suppliers network: multiple sourcing N2O
Global EM supply network
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Linde global suppliers network: multiple sourcing NH3
Global EM supply network
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Linde global suppliers network: multiple sourcing SiH4
Global EM supply network
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Linde global suppliers network: multiple sourcing He
Global EM supply network
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Linde global suppliers network: distributed portfolio
Global EM supply network
BCL3
B2H6
Cl2DCSHalocarbons HBrLaser gasNH3
Si2H6
WF6
BF3
ClF3
D2
GeH4
HClHF HeSiH4
TCSXe
N. America Asia
Cl2DCSF2 MixHalocarbonsHBrHCl NF3
NH3
SF6
Si2H6
CHF3
F2
GeH4
HCDS HeN2OPOCl3SiH4
TCS
Europe
DopantsHe N2O TCS
HCl HF NH3
Xe
>50+ sources globally
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Sourcing
• Access to 4/7 Global suppliers representing 67% of HCl capacity
• Distribute prime source to the respective region, as well as introduce new source for BCP
Assets
• Variety of fleet- ISO tube- Drum, Y Tonner, Cylinder
• Capability in ISO tube service
• Periodic testing, maintenance, and upgrading of assets in line with global standards
Quality
• Proven track record of bulk HClsupply to semiconductors customers across the world for several decades
• Multiple sources – same final product
Global Capacity 2017 (>17.5 Ktons)
Multiple sources – same product example: HCl
Material supply by trading
Supplier D (10%)
Supplier A (29%)
Supplier C (17%)
Supplier B (29%)
Supplier E (6%)
Supplier F (5%)Supplier G (4%)
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Manufacture
• High volume product – must be made close to source for cost
• Manufacture in 4 countries to be close to customer
• Same process in each location
Assets
• Variety of fleet- ISO tube- Drum, Y Tonner, Cylinder
• Capability in ISO tube service
• Periodic testing, maintenance, and upgrading of assets in line with global standards
Quality
• Proven track record of bulk N2O supply to semiconductors customers across the world for several decades
• Multiple local plants – same final product
Material supply by manufacture Multiple local plants – same process example: N2O
#4 (14%)
Linde (31%)
#3 (16%) #2 (20%)
#5 (4%)#6 (2%)
Others (11%)
#7 (2%)
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Conclusion: Quality and supply chain work together
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LindeEstablish & certify QMS
Align with EICC
Ensure business continuity
Perform incoming material QC
Control production quality
Manage deviations from specification
Manage process changes
CustomerManage deviations from specification
Manage process changes
Understand customer requirements
Check & develop requiredcapability
Raw materials
Manage deviations from specification
Manage process changes
Qualify suppliers
Qualify products
Manage supplier performance
Quality: Holistic, collaborative approachWe achieve electronics industry quality standards with close collaboration throughout the supply chain