Semiconductor Fabrication Energy Model

Photo of James Babyak, Jose Romero, Genevieve Turco Students: James Babyak, Jose Romero, Genevieve Turco

Sponsor: Texas Instruments

Date: Fall 2009

Requirements:
Theoretical utility consumption is defined as the target consumption level. The model is based both on existing industry standards and on TI's goals. The actual utility consumption is shown so that differences between actual and theoretical levels can be examined. Additionally, TI has requested that these outputs appear in both graphical and tabular form.

Problem:
Texas Instruments operates two Dallas area metal on silicon (MOS) semiconductor facilities called DMOS6 and DMOS5N, the former being the largest, most advanced, and most recently constructed. Both plants incur multimillion dollar utility bills each year, and TI is working to reduce the consumption levels both to save costs and to better the environment. Several measures are currently in place to recycle water and air in the plant, but TI still strives to improve further. TI has requested the delivery of a working Excel model that shows actual and theoretical utility consumption per month for the period of a year for these plants.

Solution:
The team delivered an Excel model to TI and has completed a refinement process. The program takes inputs from the user, runs a Visual Basic program that models plant components, and then outputs usage of three utilities (water, electricity, and natural gas) per month per sector. The refinements include making the model globally applicable by adding entries for additional building floors in the input tables, adding an SI units option, and finally writing a complete set of instructions to accompany the Excel file.

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