Steady Progress in Digital Transformation (DX)
Under the SUMCO Vision, SUMCO aims to be a leading company in the area of digital transformation (DX). We established the AI Promotion Division in 2018 and have actively pursued initiatives such as building a system to analyze and predict improvements in productivity and quality in real-time by collecting quality and process information for each stage of the production process as Big Data. We are also working to improve equipment productivity and labor productivity, aiming to enhance competitiveness in areas with the most in-demand commodities and strengthen our profit base.
Message from the General Manager of the AI Promotion Division
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The establishment of SUMCO’s AI Promotion Division dates back to 2018, when the term “DX” was not yet widely used and generative AI was still limited to academic research. From the outset, the objective was not simply to introduce AI itself, but to position it clearly as a means of improving factory productivity. One unique feature of the Division is that, in addition to IT-related functions, it also incorporates departments with extensive knowledge of manufacturing processes as well as departments responsible for quantifying and reducing equipment- and personnel-related losses. In addition to building a factory data infrastructure based on RTM,* close collaboration with production divisions enabled improvements at our main 300 mm wafer plants in 2021, including investment suppression effects exceeding ¥30 billion and profit creation effects exceeding ¥4 billion annually. Since then, we have continued to promote smart factory initiatives across all plants, achieving annual labor-saving effects exceeding ¥1 billion, while also preventing human error and reducing burdensome operations. We are also focusing on accelerating the development and production support of high-value-added products, one of SUMCO’s strengths. These efforts include the development of AI utilization platforms for engineers and the in-house deployment of RTM + AI systems capable of automatically identifying processes requiring tuning. AI will continue to evolve going forward. Through the provision of high-quality silicon wafers, which serve as a foundational material supporting these technologies, SUMCO aims to contribute to society.
- RTM: Real-Time Monitoring, which monitors data and system conditions in real time
Takeo Katoh
Director, Senior Managing Executive Officer / General Manager of AI Promotion Division
AI Promotion Division Mission Boosting SUMCO’s
DX Promotion Strategy
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At SUMCO, we are working to achieve real-time monitoring and automation of production processes and to establish a production capability and production plans capable of flexibly meeting market demand fluctuations. We are also seeking to expand the areas where AI is employed. By realizing rapid data analysis in the technology fields of our leading-edge products, and speeding up the time from development to mass production, we aim to enhance the agility and competitive advantage of the entire organization through the promotion of DX.
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Operation Efficiency Through DX Tools and Other Solutions
DX tools is the general term used at SUMCO for tools that support operation efficiency, including BI tools, RPA, and workflow systems.
The results so far are work savings of more than 184,000 hours a year.
By continuing to introduce DX tools of various kinds and making them a regular part of operations, we will seek to improve product quality along with work efficiency.
Obtaining DX Certification (Since 2021)
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As a result of these efforts, SUMCO has been selected as a "DX Certified Operator" by the Ministry of Economy, Trade and Industry’s Digital Transformation Certification, recognizing that SUMCO has the vision, strategy, and framework, etc. necessary to transform its business through digitalization.
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Smart Factories Envisioned by SUMCO
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AI and DX have been deployed across all areas of factory operations, achieving cost reductions through improved productivity and labor saving.
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Evolution of Data Analysis Through AI
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Semiconductor wafers used in leading-edge semiconductors are required to have even higher precision and quality than ever before, making the analysis of even the slightest defects and variations increasingly important. AI-based data analysis systems are being increasingly introduced into 300 mm production lines and are delivering results through quality improvements and significant reductions in engineer work-hours for data processing and analysis.
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Division SE System
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SUMCO accepts non-IT personnel from user divisions into the AI Promotion Division as internal exchange trainees. After receiving education and training on practical IT and DX tools used in manufacturing and business operations, participants return to their respective divisions and play active roles as key personnel in continuously promoting DX. This system was launched in 2021 and has now reached its ninth class. To date, more than 50 employees have completed the program.
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Initiatives for Developing IT Human Resources
As part of efforts to strengthen competitiveness in the digital era, SUMCO actively supports employees in obtaining IT-related certifications. Through measures such as subsidies for examination fees and incentive programs for certification acquisition, we promote employees’ self-development, resulting in a steady year-by-year increase in the number of certified employees. Going forward, we will continue to promote the development of advanced IT human resources through ongoing human resource development initiatives.
