Safety Critical: Driving Quality and Supply Chain Requirements for Automotive Electronics

Dr. Anish Tolia, VP of Global Marketing, Linde ElectronicsSeptember 20, 2017

Safety Critical

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

Google

Apple

Uber

Facebook

Twitter

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

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

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

Automaticbraking

Airbagdeployment

Enginecontrol

Electricpower steering

Electronics ubiquitous on carsSafety Critical

Electronicthrottle control

Blindspotdetection

Electronic stabilitycontrol

Transmissioncontrol

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

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

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

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%

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

Quality: Between raw materials and the cleanroom

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

Between the variability of the raw material source…

Fluorspar mine: HF, NF3, SF6, CF4, etc.

Between the variability of the raw material source…

Tungsten mine: WF6, WCl5

Between the variability of the raw material source…

Germanium mine: GeH4, Ge2H6

…and the precision of manufacturing

…and the precision of manufacturing

Material suppliers like Linde are the quality gatekeepers

Source Quality Use

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

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

Production plant for Electronic Specialty Gases: Cylinder preparation

Production plant for Electronic Specialty Gases: Cylinder filling

Production plant for Electronic Specialty Gases: Blending

Production plant for Electronic Specialty Gases: Analysis

Supply chain: Ensuring business continuity

Supply interruptions can be caused by natural disastersFukushima Earthquake and Tsunami: 2011

Supply interruptions can be caused by human eventsBeijing Olympics: 2008

Supply interruptions can be caused by human eventsG20 Summit: 2016

Supply interruptions can be caused by human eventsTianjin Port Explosion: 2015

Loma Prieta Earthquake: 1989

And they can happen close to home

And they can happen close to homeHurricane Harvey: 2017

Linde global suppliers network: multiple sourcing HCl

Global EM supply network

Linde global suppliers network: multiple sourcing N2O

Global EM supply network

Linde global suppliers network: multiple sourcing NH3

Global EM supply network

Linde global suppliers network: multiple sourcing SiH4

Global EM supply network

Linde global suppliers network: multiple sourcing He

Global EM supply network

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

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%)

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%)

Conclusion: Quality and supply chain work together

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

www.linde.com/electronics

electronicsinfo@linde.com