 Semiconductors
are unique substances, which, under different conditions, can act as
either conductors or insulators of electricity. Semiconductor processors
turn one of these substances -- silicon -- into microchips, also known
as integrated circuits. These microchips contain millions of tiny
electronic components and are used in a wide range of products, from
personal computers and cellular telephones to airplanes and missile
guidance systems.
To manufacture microchips,
semiconductor processors start with cylinders of silicon called ingots.
First, the ingots are sliced into thin wafers. Using automated
equipment, workers or robots polish the wafers, imprint precise
microscopic patterns of the circuitry onto them using photolithography,
etch out patterns with acids, and replace the patterns with conductors,
such as aluminum or copper. The wafers then receive a chemical bath to
make them smooth, and the imprint process begins again on a new layer
with the next pattern. A complex chip may contain more than 20 layers of
circuitry. Once the process is complete, wafers are then cut into
individual chips, which are enclosed in a casing and shipped to
equipment manufacturers.
 The manufacturing and
slicing of wafers to create semiconductors takes place in cleanrooms --
production areas that are kept free of all airborne matter because the
circuitry on a chip is so small that even microscopic particles can make
it unusable. All semiconductor processors working in cleanrooms must
wear special lightweight outer garments known as "bunny suits". These
garments fit over clothing to prevent lint and other particles from
contaminating the cleanroom.
There
are two types of semiconductor processors: operators and technicians.
Operators start and monitor the equipment that performs the various
production tasks. They spend the majority of their time at computer
terminals, monitoring the operation of equipment to ensure that each of
the tasks in the production of the wafer is performed correctly.
Operators may also transfer wafer carriers from one station to the next,
though the lifting of heavy wafer carriers is done by robots in most new
fabricating plants.
T echnicians are
generally more experienced workers who troubleshoot production problems
and make equipment adjustments and repairs. They take the lead in
assuring quality control and in maintaining equipment. They also test
completed chips to make sure they work properly. To keep equipment
repairs to a minimum, technicians perform diagnostic analyses and run
computations. For example, technicians may determine if a flaw in a chip
is due to contamination and peculiar to that wafer, or if the flaw is
inherent in the manufacturing process.
Note: Some resources in this section are provided by the US Department
of Labor, Bureau of Labor Statistics.
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