Etch process module cost reduction accelerates tool affordability
Project snapshot
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Challenge
Achieve significant cost reduction on a mature tool platform
The customer needed a 30% reduction in tool cost while implementing improvements in process technology. The effort had to be low-risk, ensuring no process-critical components were affected, and the first prototype of the cost-reduced platform was required in just three months.
Innovation
Systematic redesign targeting high-impact areas
We analyzed the existing high-volume platform, which had grown over time with additional options, increasing both cost and component count. Key areas addressed included:
- Frame construction redesigned from tubular sections to folded sheet metal with integrated enclosures and wire harness clips, reducing part count and assembly complexity.
- Electrical and control packaging optimized to simplify integration.
- Wire harnessing rationalized to eliminate unnecessary components.
- Pneumatic, cooling, and heating systems reviewed for simplification and cost reduction.
These changes collectively reduced overall platform complexity and enabled substantial cost savings without compromising performance.
Result
Low-risk cost reduction delivered on an aggressive schedule
The redesigned platform achieved the target 30% cost reduction while maintaining all process-critical functionality. The first prototype was delivered on schedule, demonstrating that careful, systematic design modifications can significantly impact total tool cost even on mature platforms.
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