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Chip boom forces TSMC to shuffle 1,000 engineers

By Industry News
Taiwan’s semiconductor industry, the world’s second-largest by revenue after the US, has also elevated the strategic importance of the self-ruled island of nearly 24 million people that China views as part of its territory. Credit: Handout.

Thanks to soaring demand for its 5 nm chips, the Taiwan Semiconductor Manufacturing Corporation (TSMC) is planning to send more than 1,000 engineers to its facilities in Tainan’s Southern Taiwan Science Park to assist in boosted production, Taiwan News reported.

TSMC has now become the leading semiconductor manufacturing contractor in the world controlling more than 50% of the almost US$70 billion third-party fabrication market as of January 2020, according to SeekingAlpha.

While the Trump’s administration focused mainly on sidelining China for sophisticated chips, a recent problem has cropped up with big automobile companies including Ford and General Motors in dire need of semiconductors, even having to cut production.

Due to orders from Apple, Qualcomm, Advanced Micro Devices (AMD), and MediaTek, the world’s largest contract chipmaker is planning to dispatch the engineers to Tainan in five to six batches, Taiwan News reported.

The company is deploying the extra hands in order to increase its current 5 nm capacity, which stands at around 60,000 to 70,000 wafers per month, up to 120,000 wafers a month, UDN reported.

Chip shortage forces GM to expand plant closures

By Industry News

The decision to extend the shutdowns is an effort to prioritize chips for production of full-size pickups and SUVs

North American automakers are reeling from the shortage of semiconductor chips. Today’s vehicles require up to as many as 100 chips for its high-tech safety and infotainment systems. Credit: Oakland Press.

The global semiconductor shortage is starting to dent the world’s automakers where it hurts — in the pocket book.

General Motors announced this week it is extending temporary shutdowns at three of its North American plants due to the ongoing chip shortage, which is expected to shed billions off automakers’ earnings in 2021, CNBC reported.

The decision to extend the shutdowns at car and crossover plants in the United States, Mexico and Canada is in an effort to prioritize chips for production of GM’s full-size pickup trucks and SUVs, the company said Wednesday.

GM also said its Gravatai plant in Brazil will take downtime in April and May.

GM previously said the North American plants would be closed until at least mid-March, CNBC reported.

The San Luis Potosiplant in Mexico is now scheduled to be down through the end of March, while the US and Canada plants will be shuttered until at least mid-April.

The announcement comes a week after GM CFO Paul Jacobson said the chip shortage was improving, but the company still expected the delays to lower its free cash flow by US$1.5 billion and US$2.5 billion in 2021.

“GM continues to leverage every available semiconductor to build and ship our most popular and in-demand products, including full-size trucks and SUVs for our customers,” the company said in a statement.

“GM has not taken downtime or reduced shifts at any of its truck plants due to the shortage.”

At CAMI, Canadian workers build the Chevrolet Equinox, while at Fairfax, Kansas, it’s the Chevrolet Malibu and Cadillac XT4.

Chip shortage could present new US-China flashpoint

By Industry News

TSMC’s pre-eminence in the field was already becoming a point of tension in the long-standing conflict between Taipei and Beijing.

A supply-chain disruption to one of the world’s most essential technological products is quickly becoming the flashpoint for global tensions. The fallout from the Covid-19 pandemic has not just hit international markets in unprecedented magnitudes but has also affected market dynamics in almost unprecedented ways.

Originating in China, the novel coronavirus hit East Asia first. This had a massive impact on business operations in the region, from manufacturing to shipping. But by far the most important consequence of this phenomenon, and the one the world continues to reel from today, was the disruption it inflicted on the global supply of semiconductor chips.

For months now, the world has slowly been inching toward the most severe shortage of these vital devices ever experienced. Companies across industries, from mobile-phone producers to automobile manufacturers, are speaking out on the danger this trend is posing to global production.

While many fields of manufacturing were able to recover – some relatively quickly – from the shock to the system triggered by lockdowns and travel restrictions, chip production has not seen this same comeback.

Initially, manufacturers of semiconductors assumed that demand would fall drastically as global production across the board fell. However, the exact opposite actually took place. Demand for semiconductor chips boomed as cars and medical devices continued their technological advance and an increasing number of products began requiring these chips.

This miscalculation of the market has been exacerbated by the fact that chip production is, surprisingly, not a particularly widespread business. Currently, there are only three major chip producers in the world: Intel in the US, Samsung in South Korea, and TSMC in Taiwan. These companies are yet to respond to the ever-increasing demand for their product.

Already the shortage has had a ripple effect throughout the automotive industry. In the US, manufacturers have significantly cut back production because of a lack of chips for their increasingly high-tech cars.

US chip ban has had many undesired punitive effects. Image: Twitter

Several months ago, American semiconductor manufacturers began receiving frantic phone calls from auto executives at Ford, Volkswagen, BMW, Daimler-Benz, Fiat Chrysler and General Motors – every one begging them to ramp up production.

Recent news reports revealed that lack of conductors has forced GM and Ford to slash production in three US states as well as in Canada and Mexico, presenting a huge threat to these companies’ employees as well as those of their suppliers.

The crisis has already begun to extend outside mere market parameters. The repercussions to US business have attracted the attention of a host of policymakers, including US President Joe Biden’s office.

China chases semiconductor self-sufficiency

By Industry News

A priority in the Chinese Communist Party’s (CCP) 14th Five-Year Plan (2021–25) is to strengthen China’s autonomy in semiconductor production. This is in response to US sanctions restricting the supply of chips containing US technology to China. The trade war is a reminder for Chinese leadership that it can no longer rely on imports and must develop in-house core technology and pursue technological leapfrogging, especially in essential components such as semiconductors.

People look at the semiconductor products exhibited at the 2020 World Semiconductor Conference in Nanjing city, east China's Jiangsu province, 27 August 2020.

China’s demand for modern and emerging technologies is on the rise. Semiconductor imports increased to over US$300 billion in 2019 and were the country’s largest import item. China supplies just 30 per cent of its chips domestically. Chip production is a complex process involving different components and manufacturing stages. China has made progress in chip design — Huawei successfully developed its in-house premium-tiered chip, Kirin, for its 5G equipment and flagship smartphones. By some measures, Kirin is as competitive as chips made by commercial rivals Qualcomm and Samsung.

China’s real problem lies in its ability to manufacture high-end chips. Semiconductor fabrication requires high precision. The most powerful chips pack as many transistors as possible into increasingly smaller and more efficient chips. Huawei designs its own high-end chipsets but cannot produce them in-house. Not even China’s largest chipmaker, the state-backed Semiconductor Manufacturing International Corporation (SMIC) has this capability. Huawei’s Kirin chipsets are made by Taiwan Semiconductor Manufacturing Company (TSMC) using US technology and equipment.

The technological gap between China’s and Taiwan’s foundries is stark. TSMC produces high-end 5-nanometre semiconductors, while SMIC only recently acquired the 14-nanometre fabrication technology necessary to mass produce semiconductors. China’s chip manufacturing capability is at least two generations (7–10 years) behind the industry leader.

Over the years, government support has helped Chinese manufacturers develop some capacity for chip production. According to the Semiconductor Industry Association, Chinese chip manufacturers received government subsidies amounting to US$50 billion over the past 20 years ― 100 times the amount received by companies in Taiwan. Domestic companies also benefit from tax holidays, free land, preferential loans and procurement incentives. Chinese companies have churned out an increasing volume of chips and China’s semiconductor exports reached US$101 billion in 2019, a 20 per cent rise from the previous year. But these are mainly low or medium-range chips.

Geopolitics plays a role in explaining why China’s chip production trails that of Taiwan, South Korea and Japan. These three economies benefited from US capital and technology transfers, being Asian allies during the Cold War. The Taiwanese government sent its first batch of engineers to the United States for training in the 1970s, who later returned to help build Taiwan’s semiconductor foundry. TMSC’s success also owes much to its founder, Morris Chang, a Chinese-born engineer with 25 years of experience in a leading US semiconductor firm before being recruited by the Taiwanese government to start TMSC in 1987.

Advances in semiconductor manufacturing demands skills and expertise which cannot be developed overnight. When Samsung and TMSC began investing in research and development and nurturing talents in semiconductor production in the late 1970s, China had just emerged from the decade-long Cultural Revolution that trampled scientific endeavour. This legacy means that even after reform and opening began in 1978, throughout the 1980s and 1990s, China lacked skilled engineers to develop innovation in the industry.

The Chinese model of massive state investment to support strategic industries is also highly inefficient. In China, state investment traditionally led to high volumes of low-quality production, like in the steel industry. There are signs that the recent CCP-led ‘Great Semiconductor Leap Forward’ already prompted a proliferation of registrations for domestic semiconductor-related companies, averaging 200 a day. Some of these are purposely set up to benefit from government incentives.

Talent is crucial in the semiconductor industry. China’s education needs to nurture talent and innovation in basic science to fill the technological gap in semiconductor fabrication technology. Currently there is a shortfall in manpower of around 200,000 in the Chinese industry. Skilled researchers specialising in advanced chip development and experienced managers are lacking. Recent years have seen China stepping up its effort in recruiting overseas engineers and senior executives from leading semiconductor firms. But a lot of these recruitments have been short-lived.

China should rethink its semiconductor localisation strategy. Localising supply chains may reduce China’s reliance on foreign technology, but it will be costly and commercially unviable. Taiwan’s lead in semiconductors is a story of focusing capabilities in a segment rather than the entire supply chain. In terms of high-end chip fabrication technology, it will take Chinese chipmakers another 7–10 years to catch up with rivals. And even then, they are chasing a moving target. TSMC is now moving ahead to develop the 3-nanometre production process.

China could leverage technological change and find catch-up opportunities elsewhere. To move up global value chains, it should focus on other areas such as artificial intelligence chips — a new technological field with fewer established incumbents. Chinese technology companies like Alibaba and Huawei have already made a head start in producing these chips to be used in 5G networks.

Yvette To is a Postdoctoral Fellow in the Department of Asian and International Studies at the City University of Hong Kong (CityU).