TSMC’s Hsinchu 3nm fab operates 24/7, producing advanced semiconductors for smartphones, AI chips, and automotive electronics. The fab relies on 500+ PLC-controlled systems to regulate critical processes such as lithography, etching, and deposition—all of which require stable, uninterrupted power to ensure wafer quality. The legacy PLC power supplies presented critical operational challenges:
- Unstable Voltage Output Causes Wafer Defects: The legacy power supplies had a voltage regulation accuracy of only ±2%, leading to voltage fluctuations that disrupted precise semiconductor processes. This resulted in a 3.2% wafer defect rate, costing TSMC €4.8 million annually in wasted materials and rework.
- Poor Load Handling Triggers Shutdowns: The old power supplies couldn’t handle sudden load changes from high-power PLC-controlled equipment (e.g., lithography machines), causing 8-10 unplanned shutdowns monthly. Each shutdown lasted 1-2 hours, resulting in €200,000 in lost production revenue per incident.
- Inadequate Compatibility with Smart Systems: The legacy power supplies lacked digital communication capabilities, unable to integrate with TSMC’s smart factory monitoring system. This required manual monitoring of power status, increasing operator workload by 25% and delaying the detection of power anomalies.
- High Maintenance Costs in Cleanroom Environments: The legacy power supplies generated excessive heat (up to 65°C) and had a mean time between failures (MTBF) of only 18,000 hours. In the fab’s ISO 5 cleanroom environment, maintenance and replacement required specialized cleanroom protocols, increasing annual maintenance costs to €1.2 million.
“Stable power is the foundation of high-precision semiconductor manufacturing—even microsecond voltage fluctuations can render an entire batch of wafers unusable,” said Dr. Chen Wei, TSMC Hsinchu Fab Operations Director. “Our legacy PLC power supplies were too unreliable to meet the demands of 3nm production. We needed a high-performance power supply solution that could deliver ultra-stable voltage, handle dynamic loads, integrate with our smart systems, and reduce maintenance costs.”
ABB SAFT183VMC Power Supply: Ultra-Stable Power for Semiconductor PLC Systems
After evaluating solutions from Siemens and Phoenix Contact, TSMC selected the ABB SAFT183VMC power supply for its ultra-precise voltage regulation, high load-handling capacity, digital communication capabilities, and cleanroom-compatible design. Key features addressing TSMC’s pain points include:
- Ultra-Precise Voltage Regulation: The ABB SAFT183VMC power supply offers voltage regulation accuracy of ±0.1%, ensuring stable power output for PLC-controlled semiconductor equipment. This eliminates voltage fluctuations, reducing wafer defects and improving process consistency.
- High Dynamic Load Handling: With a peak load capacity of 200% for up to 5 seconds, the SAFT183VMC easily handles sudden load changes from lithography machines and other high-power equipment. This prevents unplanned shutdowns and ensures continuous production.
- Seamless Smart Factory Integration: Supporting PROFINET and Modbus TCP protocols, the SAFT183VMC integrates seamlessly with TSMC’s smart factory monitoring system. It provides real-time power status data (voltage, current, temperature) and sends alerts for anomalies, eliminating manual monitoring and reducing operator workload by 25%.
- Cleanroom-Compatible & Low-Heat Design: The power supply features a fanless design with an operating temperature range of -25°C to 70°C, generating minimal heat (max 45°C) and avoiding particle generation—fully complying with ISO 5 cleanroom standards. Its sealed enclosure prevents dust accumulation, increasing MTBF to 150,000 hours.
- Redundant Power Protection: The SAFT183VMC supports N+1 redundancy, allowing multiple power supplies to work in parallel. If one unit fails, others automatically take over, ensuring uninterrupted power supply and further enhancing production uptime.
Results: Higher Uptime, Fewer Defects, Lower Costs
Six months after deploying the ABB SAFT183VMC power supply, TSMC’s Hsinchu 3nm fab achieved significant operational improvements:
| Metric |
Before ABB SAFT183VMC Power Supply |
After ABB SAFT183VMC Power Supply |
Improvement |
| Production Uptime |
99.72% |
99.98% |
0.26% Improvement (22.78 Fewer Downtime Hours Annually) |
| Wafer Defect Rate |
3.2% |
0.48% |
85% Reduction |
| Monthly Power-Related Shutdowns |
8-10 |
0-1 |
95% Reduction |
| Annual Maintenance Costs |
€1.2 Million |
€360,000 |
70% Reduction |
| Mean Time Between Failures (MTBF) |
18,000 Hours |
150,000 Hours |
733% Increase |
“The ABB SAFT183VMC power supply has been a critical upgrade for our 3nm production line,” Dr. Chen said. “The ultra-stable power output has drastically reduced wafer defects, and the redundant design ensures we can maintain continuous production even in the event of a power supply issue. This has not only improved our operational efficiency but also strengthened our ability to meet customer demand for advanced semiconductors.”
David Lin, ABB’s Asia Pacific Semiconductor Automation Product Manager, commented: “Semiconductor fabs require power supplies that deliver absolute stability, reliability, and seamless integration with smart systems. The ABB SAFT183VMC power supply is engineered to meet these demanding requirements, helping foundries improve production uptime, reduce defects, and lower operational costs.”
TSMC plans to deploy the ABB SAFT183VMC power supply across 12 additional 3nm and 2nm fabs in Taiwan, Japan, and the United States by 2037, targeting 99.99% production uptime and a 90% group-wide reduction in power-related equipment failures.
