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Semicon Remanufacturing Solutions - Multi-Brand Expertise

The new vacuum pump remanufacturing service from Pfeiffer for semiconductor manufacturing. Don’t stop business, reduce downtime risk.

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In vacuum pump remanufacturing, precision, repeatability and quality is everything. But unfortunately, not always given. Remanufacturing processes may vary, which leads to unpredictable downtime. With our unique vacuum pump remanufacturing service, Pfeiffer Vacuum+Fab Solutions can deliver repeatability of your processes, while providing the same excellent quality, pump after pump after pump.

Only Pfeiffer remanufactures vacuum pumps to the IATF 16949:2016 (International Automotive Task Force) automotive quality standard (certification pending) in selected service centers. Our remanufacturing approach uses the four core principles of the automotive world class standards in the field of remanufacturing vacuum pumps. These four core principles are: failure mode effects analysis, measurement system analysis, statistical process control, and manufacturing part approval.

The no. 1 priority given to all suppliers is the reduction of unscheduled downtime.
Global director of fab operations from a worldwide leading semicon company

Benefits of the Pfeiffer remanufacturing program in detail

High quality

  • Highly reliable vacuum pump remanufacturing
  • World-class automotive quality standard IATF 16949:2016
  • Defined process to ensure that every vacuum pump receives the same treatment

Fast and predictable

  • Fast and predictable remanufacturing lead times and on-time delivery by the Pfeiffer lean flow system of remanufacturing and RFID tracking
  • Online real-time monitoring of the remanufacturing process
  • Push notifications on mobile devices

Savings potential

  • Predictable reliability helps eliminate unscheduled downtimes
  • Lower costs per wafer
  • Helps to reduce wafer scrap risk

Pfeiffer remanufacturing vs. standard service

Value features
Third party
Original manufacturer
Pfeiffer
Vacuum pump repair only
x
 
 
True remanufacturing
 
x
x
ISO 9001:2015 certification
x
x
x
Compliance with IATF 16949:2016
 
 
x
Process engineering
 
x
x
Structured risk analysis of whole process
 
 
x
Analysis of vacuum measurement system
 
 
x
Statistical analysis of process data
 
 
x
Standard tool calibration
x
x
x
2D measuring of vacuum pump
x
x
x
3D measuring of vacuum pump
 
 
x
Lean processes
 
x
x
RFID real-time tracking of entire remanufacturing process
 
 
x
Push notifications on mobile devices during remanufacturing process
 
 
x
Spare parts inventory managed by Pfeiffer
 
 
x
RFID spare parts inventory control
 
 
x
Single-piece flow remanufacturing
 
 
x
Real-time balanced flow monitoring
 
 
x

Annual savings: $900,900

Assumption: 2% returned capacity buffer allowed for even just 0.1% increased manufacturing capacity

See complete calculation

Pfeiffer multi-brand remanufacturing solution

Applying the four core principles of the world-class automotive standards of APQP (Advanced Product Quality Planning) in the world of remanufacturing vacuum pumps.

The remanufacturing of each vacuum pump follows exactly these four principles. Thus, every vacuum pump receives the same treatment. Eliminating any variations within the remanufacturing process delivers products with the same quality every time. Still, every remanufactured vacuum pump is subjected to three-dimensional measuring using certified methods to make sure everything is within exact tolerances.

These four core principles are:

  • 1. Failure mode effects analysis

    A formalized and structured method of proactive risk analysis of each process and component, completed before the respective process is executed and the component is mounted.

    Failure mode effects analysis

  • 2. Measurement system analysis

    A formalized and structured method of evaluating not only the performance of the vacuum measurement equipment but also the environment and the users to make sure that all measurements taken are within the APQP standard (variation caused by the overall measurement method is 10% or less of the allowable tolerance).

    Measurement system analysis

  • 3. Statistical process control

    A formalized and structured method of statistical analysis of process data. A higher-level way to know that all processes and components meet the required results and remain in control. Allows for proactive adjustments and corrections well before defects occur. Very early warning method of process drift.

    Statistical process control

  • 4. Production part approval

    A formalized and structured method for strict quality control of all components. Seeks to eliminate defects created by supplier products.

    Production part approval

Customer success story

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13% increase in the average uptime with zero capital investment

Our quality has already proven to be successful among many of our customers. The reasons why customers decide to use the remanufacturing service from Pfeiffer vary. Yet, they all have the same objectives: avoid unscheduled downtime and improve performance.

One of our customers had the service performed by a third-party vacuum pump service provider. However, the customer was no longer satisfied with the provided service. The third parties’ lower pricing did not make up for the high cost of unscheduled downtime caused by the poor rebuild quality, which inevitably and adversely affected manufacturing.

After implementing the Pfeiffer remanufacturing solution, the uptime of our customers’ vacuum pump fleet increased by an average of 13%, with zero capital investment.

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FAQ

What could a transition plan look like if I want to switch from a previous service plan?

We have a tested and proven transition plan that ensures a smooth transition from the previous supplier to Pfeiffer – with no service interruptions.

We are flexible on the time frame we require to take over your vacuum pump service (less than 30 days, 60 days, or 90 days). In the process, we have defined three phases: planning, knowledge transfer, service launch.

The following steps are completed per phase:

1. Planning

  • Awarding of contract
  • On-site badge and training
  • Information on required shipping procedures

2. Knowledge transfer
  • Familiarization with our shipping requirements
  • Declaration of contamination documents
  • Understanding of Production Order (PO) issue procedures and approval chain

3. Service launch
  • Completion of reporting procedures and criteria
  • Tracking of Key-Performance-Indicators (KPIs) and reporting to Points of Contact (POCs)
  • Quarterly scheduled meetings to ensure and align on cost goals, Return on Investment (ROI), warranties, and performance

What are the seven steps in remanufacturing?

At Pfeiffer, we use a 7-step process for vacuum pump remanufacturing. For each step, we allocate two hours that affords managed capacity, consistent turn time, and high-quality product. These steps include:

1. Disassembly
2. Decontamination
3. Final cleaning
4. Presentation
5. Module assembly
6. Final assembly
7. Testing

Our lean flow system delivers to our customers an expected level of performance, quality and delivery every time.

What does the Pfeiffer lean flow system mean in detail?

The Pfeiffer lean flow system is designed to be a fully flexible, fast and scalable remanufacturing system. RFID tracking of the entire manufacturing process allows for reliable remanufacturing lead times and on-time delivery. Thanks to this, you get:

  • Online real-time monitoring of the remanufacturing process
  • Push notifications on mobile devices

Can remanufacturing solutions from Pfeiffer only be used for Pfeiffer vacuum pumps?

No, the remanufacturing can be used for nearly any vacuum pump brand.

Is Pfeiffer IATF-certified?

Our production company Ateliers Busch S.A. in Chevenez, Switzerland, is already certified according to IATF 16949:2016.

Can the remanufacturing approach from Pfeiffer only be used when upgrading to a new fleet of vacuum pumps?

No, it can be used not only for a new fleet of vacuum pumps, but also for your already existing one.

What are the details of the remanufacturing value calculation?

How can better availability and its value be calculated?

1. Better availability calculation

The number of vacuum pumps sent back for repair can be reduced by a minimum of 14%. What does that mean for the manufacturing capacity of the fab?

In a fab that runs crash to crash, 14% fewer repairs would mean 14% fewer crashes.

  • With 14% fewer crashes at an average of 20 hours for Mean Time to Repair (MTTR), the fab’s operating time increases by 680 hours:
    250 - 216 = 34 * 20 hours = 680 hours
  • Total available manufacturing time annually is 8,760 hours
    680 hours / 8760 hours = 8% improved equipment availability
  • If we assume quadruple redundancy of the entire fab = 8% / 4 = 2.0% better availability


2. What is the value of this 2% improved availability?

Assumptions:
  • Semi fab has $1,000,000,000 revenues
  • The net profit of the fab is 10% EBIT
  • Total fab costs are $900,000,000
  • The fab manufactures 1,000,000 wafers annually
  • Cost per wafer = total fab costs / # wafers produced = 900,000,000/1,000,000 = $900 per wafer cost


3. The remanufacturing value calculation

  • Assumption: 2% returned capacity buffer allowed for even just 0.1% increased manufacturing capacity
  • Cost per wafer = total fab costs / # wafers produced = 900,000,000/1,001,000 = $899,1 per wafer cost ($0,90 saving)
  • Annual saving: $0,90 * 1,001,000 = $900,900