Launching a chip test centre in Penang

The challenge

Build an additional test centre in Malaysia for the final testing of chips made at other Bosch sites, and bring it into operation. Building, manufacturing, IT, logistics and quality all had to work towards the same plan.

The technology

Frontend and backend: chipmaking has two halves. In the frontend, the circuits are built up layer by layer on silicon wafers in clean rooms, in Bosch’s case in its wafer fabs in Dresden and Reutlingen. In the backend, the wafers are cut into individual chips, assembled into packages and tested before they go to customers.

What Penang does: it is a backend site for the final test of chips and sensors made at other Bosch sites, especially the 300 mm fab in Dresden. It tests automotive ICs and MEMS sensors and has to meet the strict quality and reliability requirements of the automotive industry. Bosch describes it as a fully connected plant and one of the most advanced semiconductor test centres in Southeast Asia, bringing its production closer to Asian partners and customers and shortening delivery routes.

Where the chips end up: in electronic control units for airbags, electronic stability control (ESC), parking and driver assistance, and for electric and combustion powertrains.

Why Malaysia: Malaysia handles an estimated 13% of the world’s semiconductor backend work, and Penang has a dense network of packaging, assembly and test companies. The centre covers more than 18,000 m² of clean rooms, offices and labs. Bosch invested €65 million in the first stage and plans around €350 million in total by the mid-2030s, with up to 400 associates.

What I did

• Worked as a member of the project lead team in the PMO.
• Helped create the project charter and the project management plan.
• Created and helped create project documents: templates, lessons-learned records and a change-management workflow.
• Kept the schedule and the dependencies between the workstreams up to date.
• Tracked risks and prepared status reports for the steering committee and senior management.
• Coordinated project information between teams in Germany and Malaysia.
• Prepared and followed up workshops and quality-gate meetings.

Result

The test centre opened in August 2023 and is in operation.