Operations
/ Electronics & Semi-Conductors [ Remote ]
3 hours
SME Advisory – Semiconductor Fab & OSAT Facility Program Support
CLIENT:
A Global Management Consulting Firm
CONSULTANT:
He is an engineering and project management professional with over 20 of experience, he has delivered complex, high-value infrastructure projects across the semiconductor and industrial sectors. At Exyte Singapore, he played a key role in the $2.3 billion Micron Fab 10A project, overseeing design, engineering, equipment installation, and commissioning. His responsibilities included estimating power and automation system requirements, preparing detailed single-line diagrams (SLDs), layout drawings, and performing gap identification and risk assessments. He engineered instrumentation and automation packages for critical cleanroom zones such as bulk gas, solvent, and acid rooms, ensuring seamless integration with SCADA, IIoT, and FMCS systems to meet stringent process safety requirements. He facilitated the implementation of the Automatic Material Handling System (AMHS) for 300mm wafer transport, supervised vendor qualification, maintained consistent BOMs, and improved procurement accuracy. Through cost-benefit analysis and strategic planning, he optimized project margins and working capital. He has led various electrical, instrumentation, and automation projects across the energy, defense, and industrial sectors across India, Southeast Asia, and the Middle East
ASSIGNMENT:
The client had sought expert analysis on the establishment of new semiconductor Fabrication (Fab) and Outsourced Semiconductor Assembly and Test (OSAT) facilities, aiming to understand the cost structure, technology roadmap, and growth potential of their semiconductor division. The focus was on evaluating engineering process efficiencies, operational scalability, and market dynamics in both wafer fabrication and assembly/test services amid intensifying global demand for advanced nodes and heterogeneous integration. The requirement included comparing initial capital expenditures and ongoing operating costs of greenfield Fab and OSAT setups against benchmarks in established markets, and identifying cost‐optimization opportunities in equipment procurement, wafer yields, and utility usage.
OUTCOME:
The engagement enabled the client to understand the following:
1. Comprehensive Should-Cost Model
Delivered a validated cost framework that enabled the client to objectively evaluate design firm proposals across all technical packages and facility types.
2. Benchmarking Report
Provided comparative cost data and actionable insights to support accurate budgeting and effective cost control throughout the project lifecycle.
3. Negotiation Toolkit
Equipped the client with tactical inputs and industry-aligned negotiation strategies to maximize value and ensure fair commercial terms in contracts with design firms.
4. Strategic & Operational Guidance
Offered high-level advisory services on design planning, execution methodologies, vendor structuring, and long-term operational readiness for Fab and OSAT facilities.
5. Risk Mitigation
Identified potential budgetary, scope, and resourcing risks early and provided targeted recommendations to mitigate them and maintain project momentum.
6. Stronger Vendor Management Capability
Strengthened the client’s ability to proactively manage design partners by establishing clear expectations, benchmarks, and accountability frameworks.
1. Comprehensive Should-Cost Model
Delivered a validated cost framework that enabled the client to objectively evaluate design firm proposals across all technical packages and facility types.
2. Benchmarking Report
Provided comparative cost data and actionable insights to support accurate budgeting and effective cost control throughout the project lifecycle.
3. Negotiation Toolkit
Equipped the client with tactical inputs and industry-aligned negotiation strategies to maximize value and ensure fair commercial terms in contracts with design firms.
4. Strategic & Operational Guidance
Offered high-level advisory services on design planning, execution methodologies, vendor structuring, and long-term operational readiness for Fab and OSAT facilities.
5. Risk Mitigation
Identified potential budgetary, scope, and resourcing risks early and provided targeted recommendations to mitigate them and maintain project momentum.
6. Stronger Vendor Management Capability
Strengthened the client’s ability to proactively manage design partners by establishing clear expectations, benchmarks, and accountability frameworks.