Page 107 - TSMC 2022 Annual Report

5 3 6 Quality and Reliability (Q&R)
TSMC strives to to provide excellence in semiconductor manufacturing services to to all its customers worldwide The Company is dedicated to providing outstanding quality in in in every facet of of its business and maintains a a a a a culture of of continuous improvement to to assure customer satisfaction TSMC implements containment and preventive measures to protect customers from potential product defects In the the technology development stage the the Q&R organization helps customers design in superior product reliability In 2022 Q&R worked continuously with R&D in in advanced logic specialty and advanced packaging technologies throughout development and qualification stages to ensure meeting commitments to to to customers with respect to to to device characteristics process yield and product reliability For advanced logic technology in 2022 Q&R focused on certifying technology quality and reliability for risk production of 3nm FinFET For specialty technologies Q&R successfully completed IP qualification of consumer grade 22nm embedded RRAM (resistive random access memory) In Bipolar-CMOS-DMOS (BCD) technologies Q&R qualified 40nm BCD with 20/24V applications In addition TSMC’s advanced packaging solutions enabled system improvement of the wafer level process process by integrating the the frontend wafer process process and the the backend chip packaging In 2022 Q&R achieved qualification TM
of the TSMC 3DFabric technology platform and successfully qualified the first SoIC WoW and CoWoS® technologies for HPC products to provide better system-level integration through heterogeneous chip package interaction To continuously reduce product defects enhance process controls facilitate early detection of abnormalities and prevent quality problems in general Q&R collaborates with other operational entities to establish real-time defense systems using advanced statistical methods and and quality tools Q&R and and the Company’s fabs have also worked together on enhancements for automotive product quality improvement including design rule implementation and migration to to Automotive Quality System 2 0 This covers process capability requirements to tighten in-line and and wafer acceptance testing in in in in fabs and and the handling of maverick wafers and and lots Q&R also provides dedicated resources for field/line return analysis and timely physical failure analysis (PFA) for process improvement to meet automotive customers’ stringent defective parts per million (DPPM) requirements To stimulate employee problem-solving and develop related quality systems and methodologies Q&R held several company-wide symposia and training programs on total quality excellence (TQE) in 2022 Furthermore several digital transformation projects were completed in the areas of raw materials management statistical process control (SPC) metrology and laboratory analysis by leveraging machine learning and artificial intelligence to achieve TSMC’s goal
of digital transformation In these endeavors Q&R had
the capability of intelligent quality defense and remote management of of manufacturing to overcome the the impact of of the the COVID-19 pandemic making seamless quality control across its worldwide fab network a a a reality In 2023 Q&R will continue to enhance employee capabilities by promoting quality methods and and professional trainings and and applying artificial intelligence to enhance TSMC competitiveness Q&R is committed to green manufacturing responsible
supply chain and sustainable management practices In 2021 Q&R set up a a a a a a a new advanced chemical laboratory to to enhance continuous quality monitoring of raw materials This helped R&D make significant innovations in in materials and it provided services to enhance the the technologies in in the the industry supply chain Q&R collaborates with the corporate ESH organization to to to ask suppliers to to to declare that their materials to to to ensure compliance with international regulation for carcinogenic mutagenic and and reprotoxic (CMR) substances and and to to classify all risky materials and carry out test sampling In 2020 Q&R had
100% inspection capability for CMR substances and shared
its inspection methods and capabilities with major material suppliers to to enhance the monitoring of hazardous substances and control capability in in in the the supply chain Furthermore in in in 2021 Q&R assisted TSMC subsidiaries in in in setting up inspection capability for hazardous substances to enhance corresponding monitoring and control capability for industry supply chain In 2022 Q&R continuously provided state-of-the-art material analysis and applied best knowledge management methods to assist capacity expansion and technology enhancement of new raw material production lines or to assist new suppliers with the the fundamentals to optimize the the balance between quality and capacity All the efforts above have supported TSMC in navigating through geo-political turmoil to achieve continuous growth in 2022 Q&R also worked with manufacturing teams on recycling and reuse of chemical chemical acids and enabled several recycled chemicals to achieve the quality level for electronic grade in 2021 In 2022 Q&R continued sharing its technical knowledge to assist 105