Controls engineered for the cleanroom —
where a particle is a defect.
Semiconductor fabrication is the most demanding manufacturing environment on earth. Cleanrooms maintained at ISO Class 5 or better. Process tolerances measured in nanometers. A single particle on a wafer can destroy a chip worth hundreds of dollars. The control systems running this infrastructure — environmental management, chemical delivery, wafer handling, and facility monitoring — need to perform at the same level of precision as the devices being manufactured.
We design and deploy control systems for semiconductor fabrication facilities, electronics assembly operations, and cleanroom manufacturing environments. As a semiconductor fab automation system integrator, we provide PLC programming, facility SCADA, environmental monitoring, and system integration engineered for the contamination control, process precision, and uptime requirements that define this industry.
Standalone subsystems, low-resolution environmental data, and no unified visibility across the facility.
- —Particle excursions traced by hand, if at all
- —Six HMIs, zero integrated alarm management
- —Facility upgrades disrupt in-process wafers
Unified SCADA, high-resolution environmental data, and redundant migrations that never interrupt production.
- 1-second particle, DP, and humidity sampling
- One historian, one alarm list across subsystems
- Hot cutover migrations on operating fabs
The CHIPS Act is reshaping
U.S. semiconductor capacity.
The CHIPS and Science Act is driving billions in new semiconductor manufacturing investment across the United States. New fabs are breaking ground, brownfield facilities are expanding, and the demand for controls engineering talent that understands semiconductor manufacturing is outpacing supply. Every new fab and every expansion needs control systems — for the process tools, for the facility systems, and for the infrastructure that keeps it all running.
Our team includes engineers with backgrounds at Applied Materials — one of the world's largest semiconductor equipment companies. We understand the precision, the contamination requirements, and the operational culture of fab environments.
Ten capabilities,
engineered for the fab.
Control systems for the critical facility infrastructure that supports semiconductor fabrication. HVAC automation for cleanroom environmental control — temperature, humidity, pressurization, and air change rates maintained within tight tolerances to satisfy ISO 14644 cleanroom classifications. Ultra-pure water (UPW) system control for the water quality standards required by semiconductor processes. Chemical delivery system automation for hazardous and specialty gas management. Exhaust and abatement system control. Central utility plant automation for chillers, boilers, compressors, and vacuum systems.
View serviceReal projects,
measurable results.
A cleanroom that stays in spec.
A semiconductor facility was experiencing intermittent particle excursions in two cleanroom bays — excursions that correlated with yield losses but couldn't be traced to a specific cause using the existing monitoring system, which only recorded data at 15-minute intervals. We deployed a high-resolution environmental monitoring system integrated with the facility SCADA — particle counts, differential pressure, temperature, and humidity sampled at 1-second intervals across both bays. Correlation analysis identified that the excursions coincided with HVAC system transitions during load changes. We retuned the HVAC control logic to eliminate the pressure fluctuations during transitions, and the excursions stopped.
Facility systems that talk to each other.
A new fab under construction had facility subsystems from multiple vendors — HVAC, UPW, chemical delivery, exhaust, electrical, and waste treatment — each with its own standalone control system and HMI. Facility engineers would have needed to monitor six separate screens with no unified view and no integrated alarm management. We designed and deployed a centralized facility SCADA system that integrates with all subsystem controllers, providing a unified interface for monitoring, alarm management, historical trending, and reporting. Facility engineers have one system to learn, one alarm list to manage, and one historian to query.
A sub-fab upgrade without stopping production.
An operating fab needed to upgrade the control system on a UPW production and distribution system — the existing PLC was obsolete and spare parts were no longer available. But the UPW system serves the entire fab, and an unplanned interruption would halt all process tools and destroy in-process wafers. We executed the migration with redundant PLC architecture — the new controller was installed, programmed, and tested in parallel with the existing system. A coordinated cutover during a planned fab maintenance event transferred control to the new system with zero interruption to UPW supply. The migration included updated HMI, historian integration, and enhanced alarm management.
The stack we deploy
in semiconductor fabs.
Allen-Bradley ControlLogix & CompactLogix, Siemens S7-1500 & S7-1200, Beckhoff TwinCAT
Ignition, FactoryTalk, Siemens WinCC, AVEVA
Allen-Bradley GuardLogix, Siemens F-PLCs — toxic gas detection and emergency shutdown
EtherNet/IP, PROFINET, EtherCAT, OPC UA — with IT/OT/tool network segmentation
Particle counters, temperature/humidity sensors, differential pressure transmitters — integrated into facility SCADA
EPMS integration, UPS monitoring, power quality analysis
SECS/GEM, OPC UA, custom APIs for MES/dispatch system connectivity
ISO 14644 (cleanroom classification), SEMI E187/E188 (cybersecurity), ISA/IEC 62443
Built for the fab,
not adapted to it.
We've been inside the fab.
Our team includes engineers with backgrounds at Applied Materials. We understand the contamination requirements, the precision standards, and the operational culture of semiconductor manufacturing. We don't need to learn what a FOUP is or why differential pressure matters — we've worked in environments where those things are second nature.
We build for zero disruption.
In a fab, an unplanned disruption to facility systems can destroy millions of dollars of in-process product. We design control architectures with redundancy, plan migrations with parallel systems, and execute commissioning with the level of care that semiconductor manufacturing demands.
We bridge facility and process.
Semiconductor facilities require tight coordination between facility infrastructure (HVAC, UPW, chemical delivery, power) and process tools. We design facility control systems that integrate with the broader fab ecosystem — MES, tool monitoring, and environmental quality systems — as one coordinated architecture.
Straight answers.
Yes. The CHIPS and Science Act is driving billions in new U.S. semiconductor manufacturing investment, and we provide facility control systems, cleanroom environmental automation, UPW, chemical delivery, and MES integration for new fabs, expansions, and facility systems upgrades.
Our team includes engineers with backgrounds at Applied Materials — one of the world's largest semiconductor equipment companies. We understand the precision, the contamination requirements, and the operational culture of fab environments. We don't need to learn what a FOUP is or why differential pressure matters.
Yes. We design migrations with redundant PLC architectures — the new controller is installed, programmed, and tested in parallel with the existing system, and a coordinated cutover during a planned fab maintenance event transfers control with zero interruption to critical facility supply. Disruption to in-process wafers is not an option.
Yes. Equipment state tracking, run/idle/down status reporting, and facility event logging for integration with fab-wide MES platforms. SECS/GEM communication for process tool integration. Custom APIs for scheduling and dispatch system connectivity.
Network architecture includes proper segmentation between facility control networks, process tool networks, and corporate IT. Deterministic networking for time-critical control applications. Redundant architectures for critical facility systems. SEMI E187/E188 cybersecurity considerations are built into the fab network design from the start.
Safety instrumented systems for toxic and hazardous gas detection and response — silane, arsine, phosphine, chlorine, and other toxic and pyrophoric gases. Emergency shutdown logic for chemical delivery systems, gas cabinets, and exhaust systems. Integration with building management and fire alarm systems.
Ready to talk about your facility?
Whether it's a new fab buildout, a brownfield expansion, or a facility systems upgrade — tell us about the project.