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When the Chips

are Down:
Industry Outlook and
Policy Response to the
Semiconductor Crisis

April 2021
Introduction
Who knew how far reaching COVID-19’s impact would be? Impacts to sectors like travel
and hospitality were obvious, but who could predict that basic computing technology
spending would intensify or that changes in consumer purchasing would wreak havoc
with the global supply chain?

This paper explains how a confluence of issues, fueled by the health crisis, contributed
to the current chip shortage. It also discusses innovations that are driving the need
for greater chip capacity and production. Additionally, the analysis outlines U.S. policy
considerations, given the current market conditions, and explores semiconductor
manufacturing lead times and factory build costs.

When the Chips Are Down: Industry Outlook and Policy Response to the Semiconductor Crisis | All rights reserved. | CTA.tech/research 2
The pandemic led to unpredictable consumer
spending behaviors created by stay-at-home How COVID-19
orders, which served as the catalyst for the work,
educate and entertain-at-home trends. These Triggered a Chip
lifestyle shifts led to unprecedented purchasing
of technologies to enhance communications and Shortage in the
productivity. They also compelled manufacturers
of products such as automobiles and other Automotive Sector
recreational products to recast sales forecasts,
When the global health crisis began in early 2020,
expecting a downturn in orders as a byproduct
automotive manufacturers (original equipment
of these new trends. As 2020 unfolded and
manufacturers, OEMs), predicting a prolonged
consumer spending patterns solidified, these
economic downturn, revised sales forecasts of new
same manufacturers, attempting to circle back to autos downward and cut back on orders of supplies
pre-COVID product levels, were caught off-guard, and materials, including orders of semiconductor
exposing vulnerabilities in the global supply chain chips. According to World Semiconductor Trade
and a dependency on the offshore production of Statistics data, OEMs reduced orders by over 30%
semiconductors. year-over-year in April and May 2020 (see Figure 1).1

COVID-19 brought to light not only the U.S. The pullback had ripple effects. Suddenly freed-up
technology industry’s reliance on offshore chip semiconductor production capacities were filled
manufacturing but also how sudden fluctuations in by companies building technology to support the
consumer demand and inaccurate forecasting can thriving stay-at-home economy.
gravely impact product production outputs. It also
raised awareness for the need to grow domestic The auto industry expected a dip in new vehicle
chip production and capacity levels as the growth sales, but the opposite happened: spending
curve for technologies continues to expand. rebounded over the summer and fall of 2020,

FIG. 1 Y
 EAR-OVER-YEAR MONTHLY SALES GROWTH PERCENT CHANGE
IN AUTOMOTIVE ICS 2020-2019
20%
15%
10%
5%
0%
-5%
-10%
-15%
-20%
-25%
-30%
-35%
JAN FEB MAR APR MAY JUN JUL AUG SEPT OCT NOV DEC
Source: World Semiconductor Trade Statistics Data

When the Chips Are Down: Industry Outlook and Policy Response to the Semiconductor Crisis | All rights reserved. | CTA.tech/research 3
and auto sales bounced back quicker than foreseen. EVOLUTION OF CHIP PRODUCTION
Accordingly, OEMs attempted to scale up purchasing
Semiconductor production is an intensely precise
to backfill inventory levels. However, the lack of
and technical process, which begins with the
available chip fabrication capacity in the oversold
creation of a silicon wafer. As the industry has
fab market and insufficient availability of chips and
evolved, so too have wafer sizes, shifting from
subcomponents forced vehicle production to slow
sub-200 mm to 300 mm wafers, which offer
and, in some cases, stop (see Note 1). Market research
greater surface area. This translates to higher
firm Strategy Analytics expects global vehicle
chip production volumes and improved costs/
production to drop by 2.2 million units because of the
efficiencies (300 mm wafers offer over 2x surface
shortage, with a loss of $7.5 billion spanning the value
area than 200 mm).2 Technical advances in
chain of electronic vehicle systems.
manufacturing have also enabled 300 mm wafers
to produce leading-edge transistors using the 5
Note 1: The time from “wafer start” at the nm lithography process (see Note 2), employed in
beginning of a semiconductor production applications requiring the fastest and most efficient
run to finished chips that are ready to ship is chips available such as artificial intelligence and
measured in months. Thus, the impact of order wireless technology. In the early 2000s, wafer
delays or temporary pauses can be felt for a producers known as “fabs” began investing in the
half year or more. development of the larger wafer sizes (300 mm) as
the need for advanced chips grew. However, over
the past five years, demand for the 200 mm wafers
Technological has escalated while investment in these facilities
has slowed. Chips built off 200 mm wafers tend to
Innovations Driving be more stable and cost less compared to cutting-
edge 5 nm chips from 300 nm wafers. In addition,
Chip Demand sectors that tend to use the same chips for long
design cycles, such as the automotive sector, have
Over the past decade, the United States has many 200 mm applications, while sectors that turn
been at the forefront of developing emerging designs over more quickly, such as the smartphone
technologies like artificial intelligence (AI), cloud sector, use fewer chips from 200 mm wafers.
computing and electric vehicles (EVs). In parallel,
the market for connected and “smart” consumer
technologies has escalated, with products in the
digital health and smart home category expected
Note 2: Five nm or other chip “sizes” represent
to reach almost 200 million units shipped by 2024
commercial names given to generations of
(see Figure 2). These technological innovations are
chips of a certain size that use specific process,
driving the need for an accelerated number
architecture and design technologies and do
of sophisticated semiconductor chips.
not represent the geometry of a transistor.
The following sections detail major technologies and
trends influencing demand for semiconductors over passenger vehicle. Today’s cars incorporate advanced
the next decade. driver assistance systems (ADAS) features, such
as collision avoidance and active lane-keeping
Automotive Evolution that require arrays of sensors and processors
Two major trends underpin the increasing quotient enabling the vehicle to perceive the surrounding
of sensors, processors and other chips in the modern environment. However, even more sensors and

When the Chips Are Down: Industry Outlook and Policy Response to the Semiconductor Crisis | All rights reserved. | CTA.tech/research 4
FIG. 2 U
 NIT SHIPMENTS OF SMART HOME AND HEALTH AND FITNESS TECH
TO U.S. DEALERS, THOUSANDS
n Smart Home n Health and Fitness
250,000
200,000
150,000
100,000
50,000

2013 2014 2015 2016 2017 2018 2019 2020 2021 2022 2023 2024

processors are required for the self-driving features What’s more, 5G chips will likely find themselves in an
that are offered on a growing number of cars every increasing variety of connected consumer devices
year. Electrification — or the production of electric that leverage the advanced capabilities of the new
powered vehicles — is another trend feeding network. Cellular operators are expected to make a
automotive industry demand for semiconductors. play in the home broadband market, deploying nearly
Self-driving capabilities, ADAS features and battery 10 million fixed wireless 5G modems in homes by
power management functions found in EVs all require 2024.7 And CES 2021 featured a variety of 5G-enabled
logic and computing power, driving a growing laptops, demonstrating that the next generation of
industry-wide appetite for semiconductors. The wireless technology will not be limited to phones.
industry expects chip demand to expand dramatically
over the next five years as ADAS features become Industrial Internet of Things/Industrial
democratized and OEMs pivot production to EVs, Automation/Industry 4.0
which can require over 3000 chips per car.3
The industrial internet of things (IIoT) is bringing
about significant changes in manufacturing, logistics
Frost & Sullivan expect U.S. EV sales to reach and agriculture. These sectors are realizing greater
6.9 million units by 2025, up from 1.4 million efficiencies through automation by integrating AI,
in 2020.4 sensors, machine-to-machine communication and
robotics into their processes.

5G Wireless Consumer Ecosystem Connectivity and computing — and therefore,


The rollout of 5G consumer networks in the United semiconductors — are essential to IIoT and will see
States alone will foster a surge in demand for chips increasing demand in the coming years. Juniper
on a logarithmic scale. As with any new wireless Research predicts that IIoT connections will grow
generation, the arrival of 5G is prompting a major worldwide from 17.7 billion in 2020 to 36.8 billion in
upgrade cycle in smartphones, in which over a half 2025 largely due to demand in smart factories alone.8
billion 5G-enabled smartphones will ship to the When we consider increasing demand from other
United States over the next four years.5 According to commercial and industrial sectors, like agriculture and
the Taiwan Semiconductor Manufacturing Company logistics, near-term global chip demand projections
(TSMC), 5G phones have 30% to 40% more chips than stemming from IIoT applications will soon tally in the
their 4G counterparts.6 hundreds of billions.

When the Chips Are Down: Industry Outlook and Policy Response to the Semiconductor Crisis | All rights reserved. | CTA.tech/research 5
Cloud Computing FIG. 3 A
 SIA PROJECTED TO
The growing popularity of cloud-based services has CAPTURE NEARLY ALL
fueled a need for the construction, maintenance MANUFACTURING GROWTH
and updating of data centers throughout the globe, 2019-2030 Installed Global Wafer
where revenues are expected to reach $251 billion Capacity Projection
by 2026.9 Data centers thrive on servers, memory,
storage and network equipment and, consequently, 83%
in Asia
semiconductors. This growth has spurred fierce
competition among semiconductor companies, 82% Singapore
Japan
with eight of the 15 largest semiconductor deals
in Asia
over the past two decades occurring during the 79% S. Korea
last two years and attributed to gaining market in Asia
Taiwan
penetration into data centers.10 NVIDIA’s pending
acquisition of ARM for $38.59 billion and AMD’s
pending purchase Xilinx are but two examples. China

Europe
U.S. Losing Chip 12.5% 10.4% 10.0% U.S.

Production Market 2019 2025 2030


Source: Semiconductor Industry Association 2020 State of the

Share
U.S. Semiconductor Industry

The U.S. automobile industry’s chip shortage, Today, eastern Asia (Taiwan, South Korea,
albeit challenging and unfortunate, was Japan and China) holds the lion’s share of the
serendipitous for the tech industry in that it worldwide chip production capacity with 73%
highlighted an important concern: the United market share.13 And with rising demand from
States’ reliance on offshore chip manufacturers. technology innovations such as those previously
The United States is a leader in semiconductor discussed, demand for semiconductor capacity
innovation in several categories, accounting (manufacturing of wafers per month) is expected
for 47% of the global sales market share and to increase 56% or 10 million wafers per month
65% of the global “fabless” market according to from the current installed base by 2030.
the Semiconductor Industry Association (SIA).
However, when it comes to manufacturing If the current trajectory continues, we will fall short
capacity (i.e., chip fabrication), the United States is of meeting this demand. As of June 2020, only 50%
lagging, with a 12.5% share of global production in of fabs needed by 2030 were “in development” (this
2019, which is forecasted to drop to 10% by the end includes planned or announced, groundbreaking
of 2030 (see Figure 3).11 and production) with another 50% unplanned for.
And of the new fabs “in development,” only 6% were
slated to reside in the United States (see Figure 4).14
The global semiconductor industry is projected Intel’s announcement on March 23, 2021, of its plans
to reach $469 billion in 2021, increasing 8.4% to construct two new fabs in Arizona15 helps fill the
from 2020.12 gap, but significant opportunity remains to satisfy
the unplanned gap.

When the Chips Are Down: Industry Outlook and Policy Response to the Semiconductor Crisis | All rights reserved. | CTA.tech/research 6
Not an Easy Fix: FIG. 4 F ABS “IN DEVELOPMENT”
SHARE BY COUNTRY (%),
Systemic Issues as of June 2020

Facing the Chip Taiwan Korea


19% 15% Japan 8%
Industry and the US 6%
Supply Chain China
42% Europe 8%
Although the semiconductor shortage feels like Others 4%
a novel event, the emergence of bottlenecks did Source: BCG and SIA: Government Incentives and US
not occur in a vacuum, or overnight. While the Competitiveness in Semiconductor Manufacturing

pandemic certainly accelerated the conditions for


the present shortage, the semiconductor supply
chain contains a variety of systemic issues that
will make any quick resolution of the shortage DAMAGE FROM FIRE AT TOKYO
a difficult challenge. CHIP PLANT ADDS TO GLOBAL
CHIP SHORTAGE
Order Lead Times Lengthening In March 2021, Renesas Electronics Corp. in
Long lead times for orders of new semiconductors Tokyo reported that the damage from a fire in
are compounding the existing shortage, but this their fab plant would take three to four months
is also one of the primary systemic constraints on to repair. The company accounts for 30% of the
the chip supply chain overall. Lead time — the global market for microcontroller units used in
time from when a customer places an order to cars, with two-thirds of the chips manufactured
receiving the final product — can take between 14 at the damaged facility used by the auto
to 26 weeks to complete depending on the design industry.18
complexity of the chip, according to the SIA.16

FIG. 5 O
 VERVIEW OF CHIP DEVELOPMENT PROCESS

Source: H
 itachi17

When the Chips Are Down: Industry Outlook and Policy Response to the Semiconductor Crisis | All rights reserved. | CTA.tech/research 7
Rome Wasn’t Built in a Day, Nor Are While JIT inventory systems align raw material orders
Semiconductor Foundries from suppliers directly with production schedules to
increase efficiency and reduce waste, this strategy
The combination of long lead times and backlogs
also minimizes flexibility to respond to disruptions
for orders point to a seemingly simple solution: build
— a flaw that the present chip shortage illuminates.
more foundries and semiconductor manufacturing
plants to address the supply-demand imbalance.
JIT inventory models are also susceptible to shipping
However, with costs in the tens of billions of dollars
bottlenecks as pandemic-induced restrictions
and construction timelines charted over several
continue to make waves throughout the shipping
years, standing up new semiconductor production
industry. Notably, 7% of ocean freight is still not
facilities is no easy task.
making it out of Chinese ports, 20 which represent a
crucial step in the global chip supply chain, causing
For example, TSMC has announced plans to build
a scramble to airfreight that has been hampered by
a new foundry in Arizona as a means of diversifying
25% less cargo capacity this quarter than last year.21
the semiconductor supply chain outside of its high
Factor in a July printed circuit board factory fire
concentration in East Asia. Although construction
in Japan, as well as an October fire at Asahi Kasei
begins this year, fabs will not start production until
Microdevices’ Japanese advanced sensing devices
2024, as the current average build time for a new
plant, and the global supply chain has only become
semiconductor facility is three to five years.
more stressed for chip and component shipments to
meet companies’ JIT inventory needs.
Deep Pockets
Outside of the time investment, the costs for
building a next-generation chip factory have grown CHIP SHORTAGE IMPACT
significantly in recent years and are set to climb with EXTENDING TO BROADER TECH
the shift to more advanced chips. Intel announced in SEGMENTS
March 2021 the construction of two fabs in Chandler,
Beyond the auto sector, the chip shortage is
Arizona at a cost of $20 billion. The Arizona TSMC
affecting other segments of the technology
plant, slated to produce 5 nm chips, is expected to
sector, from smartphones to PCs and TV LCD
cost $12 billion.19 As 5 nm chips become a larger part
panels. The extent and magnitude of the scarcity
of the technology ecosystem, this will push up the
remain uncertain as OEMs continue to seek
average costs of building a new factory to between
avenues to shore chip supplies but concerns
$14 billion to $18 billion. And for the next-generation
remain prevalent.
3 nm chip, TSMC’s Taiwan fab facility, which started
construction in October 2019, is estimated to cost
$20 billion. Environmental Impact
The growing impact of climate change, especially in
Geographic Impact on Supply Chain
global chipmaking regions, is playing an increasing
As was stated, 73% of worldwide chip production role in the stability of the chip supply chain.
capacity resides in eastern Asia. Such a high Taiwan is experiencing one of its worst droughts
geographic concentration in semiconductor in decades, and companies, including TSMC and
manufacturing represents substantial risk to global United Microelectronics Corporation (UMC), were
chip supplies. The pandemic hastily highlighted the asked by the government to scale back water usage
danger of relying on one region to largely fulfill chip by 11% in February. 22
demand for a global enterprise ecosystem defined
by just-in-time (JIT) inventory strategies.

When the Chips Are Down: Industry Outlook and Policy Response to the Semiconductor Crisis | All rights reserved. | CTA.tech/research 8
Stateside, the severe winter storm that swept across review of U.S. supply chains and directs federal
Texas in late February caused blackouts at fabs Departments and Agencies to identify ways to secure
run by Samsung, NXP and Infineon.23 While TSMC U.S. supply chains against a wide range of risks and
and UMC had water trucks on hand to ameliorate vulnerabilities.” Section 3 of the EO directs four
the imposed water usage restrictions during the federal agencies to produce reports within 100 days
Taiwanese drought, the surprise of deep freezes at on risks to supply chains and recommendations to
Texas semiconductor plants underscore the need address these risks. Semiconductors are first among
for mitigation strategies to combat the substantial the four listed areas:
negative impact that adverse environmental events
can have on the semiconductor supply chain. • The Department of Commerce (DoC) to identify
risks in semiconductor manufacturing and
advanced packaging supply chains
Fabs can use up to 4 million gallons of pure • The Department of Energy (DoE) to identify risks
water per day for chip fabrication.24 in the supply chain for high-capacity batteries,
including EV batteries

U.S. Policy • The Department of Defense (DoD) to identify


risks in the supply chain for critical minerals and

Activities Affecting other identified strategic materials, including


rare earth elements

Semiconductors • The Department of Health and Human Services


(HHS) to assess risks in the supply chain for
pharmaceuticals and active pharmaceutical
The Trump administration sought forceful actions ingredients
aimed at decoupling the U.S. economy from China’s,
citing wide-ranging national security threats as a The EO goes on to require agencies to produce
means of enacting restrictive supply chain policy additional reports within one year: the DoD is
and legal changes. Roadblocks on imports, including assigned supply chains for the defense industrial
tariffs, have cost the technology industry, American base; the HHS is tasked with supply chains for the
businesses and consumers billions of dollars since public health and biological preparedness industrial
the tariffs on China began in 2017, which do not take base; the DoC and Department of Homeland
into account the cost of retaliatory tariffs or other Security are assigned supply chains for critical
tariff actions taken against trading partners. sectors and subsectors of the information and
communications technology (ICT) industrial base,
The shift in trade policy has put technology at the including the industrial base for the development of
center of the debate — especially by acknowledging ICT software, data and associated services; the DoE
that “foundational technologies” are at the apex of is tasked with supply chains for the energy sector
America’s both economic competitiveness and national industrial base; the Department of Transportation is
security. As the Biden Administration begins its term given supply chains for the transportation industrial
and commences review of global supply chains, getting base; and the U.S. Department of Agriculture
issues specific to the semiconductor industry right can is assigned supply chains for the production of
help ensure the tech ecosystem flourishes. agricultural commodities and food products.

The most direct response by the Biden administration Additionally, in November 2019, the DoC proposed
to the recent semiconductor supply chain stress broad new rules to regulate Information and
has been the Executive Order (EO) on America’s Communications Technologies (ICTS) transactions
supply chains. The EO “launches a comprehensive deemed to pose a threat to U.S. national security.25

When the Chips Are Down: Industry Outlook and Policy Response to the Semiconductor Crisis | All rights reserved. | CTA.tech/research 9
The DoC based these rules on EO 13873, Securing the chains necessitate markets free of overly burdensome
Information and Communications Technology and regulations for industry to remain competitive. For
Services Supply Chain.26 On January 21, 2021, the last this reason, government should work closely with
day of the Trump Administration, the DoC issued new the business community to ensure transparency and
interim final rules that provisionally put into place efficiency across all aspects of the regulatory and
a new set of procedural rules that could prohibit or oversight process.
unwind ICTS transactions on a case-by-case basis that
(i) involve certain categories of ICTS; (ii) are designed, When crafting new guidelines, regulations and
developed, manufactured or supplied by persons import/export rules, the responsible agencies must
owned by, controlled by or subject to the jurisdiction ensure transparency throughout the entire rule-
or direction of a “foreign adversary”; and (iii) pose an making process. A critical piece of that is working
“undue or unacceptable risk” to the national security closely with the business community and our allies to
of the United States.27 The DoC grounded its rules in keep regulations and restrictions narrowly defined,
the International Emergency Economic Powers Act with clear processes in place for stakeholder input,
and subjects violators to potentially harsh penalties. interagency review and procedures for exclusions
and exemptions.
For years, Congress has debated policies to spur
the domestic production of chips. Lawmakers have CTA supports the Administration’s EO on America’s
considered various policies that have aimed to either supply chains with an expectation of transparency and
provide incentives to companies for producing these private sector engagement. CTA president and CEO
important chips in America or make it more costly Gary Shapiro said, “Technology is the backbone of the
to produce overseas. Different pathways have been American economy and our global competitiveness,
hotly debated in Congress, and over time lawmakers and we applaud President Biden’s comprehensive,
have increasingly supported incentivizing companies open approach to reviewing our nation’s supply chain.
to build capacity and produce domestically. These Specifically, we are pleased to see the administration
incentives vary. While the Biden Administration examine our supply chain in the context of recent
recently proposed $50 billion in federal assistance world events including COVID-19.”
to boost domestic chip production, it will take
Congress to pass the legislation. At the time of this In contrast, CTA expressed deep concern with the
writing, the Senate Commerce Committee plans DoC Interim Final Rule on Securing the Information
to markup a sweeping U.S. competitiveness and and Communications Technology and Services Supply
infrastructure bill called the Endless Frontiers Act Chain rules. The ICTS interim final rules have overly
after Easter recess. Within this bill is the CHIPS for broad definitions that sweep in transactions related
America Act, specifically focused on semiconductor to everything from chips to gaming applications.
competitiveness, which some estimate may be CTA urged the DoC “to pause the proceeding to
funded as much as $300 billion. undertake a comprehensive review of the IFR and
the process that led to it before undertaking any
transaction reviews or prohibitive actions under
CTA Policy Positions Executive Order (“EO”) 13873.”

on Supply Chains Certain high-tech subsectors, including the


semiconductor industry, have been recognized as
and Trade important for national security. As such, lawmakers
are seeking to design industrial policy aided by
The cyclical nature of business, costs of government funding. Although CTA does not endorse
manufacturing and the complexities of global supply government subsidies to industry, tax incentives

When the Chips Are Down: Industry Outlook and Policy Response to the Semiconductor Crisis | All rights reserved. | CTA.tech/research 10
offered by the government have been an invaluable environment where technology’s expansion
tool for promoting industry growth. is irrefutable, overall capacity level must rise to keep
pace with demand. As the United States rolls out
To combat illegal trade practices, or to counter a plan to secure chip sourcing, the government and
foreign competition, policies must be derived in industry must work together to boost domestic
accordance with our international trade obligations production. This also means the U.S. technology
and in concert with our many global trade allies. sector must work closely with trade partners
This provides rules, guardrails and transparency for to stabilize supply. The United States must also
businesses trying to navigate trade actions. Further, maintain its strength in innovation, working to
acting with our allies — like entering into trade improve production automation capabilities that
agreements — provides a counterbalance to the enhance chip production and reduce lead times.
questionable trade practices of other global players. CTA will continue tracking events and the evolving
market conditions to understand the implications

Closing Thoughts of this critical issue.

The pandemic highlighted an Achilles’ heel, which is


our critical dependence on overseas wafer and fab
companies to fuel several high-tech industries. In an

GLOSSARY: SEMICONDUCTOR CHIP COMPANIES

COMPANY TYPE ROLE/RESPONSIBILITIES EXAMPLE COMPANIES

Manufactures semiconductor equipment


Equipment
used to design and develop semiconductor Applied Materials, LAM Research
Manufacturer
chips and components

Manufactures silicon wafers; receives Taiwan Semiconductor


Foundry or
production contracts from fabless Manufacturing Company, Samsung
Fabrication (or Fab)
companies Electronics, GlobalFoundries

Cuts wafers in individual semiconductor


Test and Assembly devices (dies); tests dies; packages into ASE Group, Amkor Technology
devices

Designs and manufactures chips in their


Integrated Device
own fabrication facility; markets their own Intel, Analog Devices
Manufacturer (IDM)
chips

Designs and markets chips while


Fabless outsourcing manufacturing to a third-party Qualcomm, Nvidia
partner(s)

Sources: Semiconductor Industry Association28; Semiconductor Engineering29; Markets and Markets30

When the Chips Are Down: Industry Outlook and Policy Response to the Semiconductor Crisis | All rights reserved. | CTA.tech/research 11
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When the Chips Are Down: Industry Outlook and Policy Response to the Semiconductor Crisis | All rights reserved. | CTA.tech/research 12
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