Challenge
A global semiconductor equipment manufacturer needed to keep pace with the demands of advanced IC nodes, transitioning from 2D to 3D designs. Critical components of equipment manufacturing required design standards that affected performance, structural alignment, and system integration. Updates to components such as mirror blocks triggered cascading changes across assemblies and could not be handled in isolation, as each design change impacted surrounding assemblies and influenced product launch timelines.
Managing Engineering Change Orders (ECOs) at this level of complexity necessitated full ownership, regulatory compliance, version control, and documentation consistent with SEMI standards. The client’s internal teams faced bandwidth constraints and lacked the specialized resources needed to implement these changes efficiently with the necessary optimization across tools, systems, and business platforms.
Solution
Quest Global deployed a structured ECO process covering validation, redesign, approval, and release. Applying cross-domain engineering expertise ensured system compatibility and SEMI standards compliance across all changes.
The team:
Created formal ECOs and associated part numbers within the product lifecycle management (PLM) system
Developed retrofit designs for mirror block assemblies, including multiple internal concepts
Conducted performance simulation and physical compatibility analysis using tools such as NX, Creo, CATIA, AutoCAD, SolidEdge, Teamcenter, ENOVIA, Windchill, and Zuken E3 Series
Finalized component geometry, materials, and tolerances in line with SEMI standards, including S1, S2, S3, S6, S8, S12, S13, S14, and S22
Updated the Bill of Materials (BOM) and added affected parts and specifications into the enterprise resource planning (ERP) system
Reviewed and validated design change requirements with the client - Completed design reviews and secured client approval
Routed ECOs for approval and promoted them into production
Digitized all ECO workflows with secure Quest Global toolchains, ensuring access control and version management within PLM and ERP platforms for regulatory compliance and internal audit readiness
Provided flexible resources with proactive support, adapting seamlessly to customized requirements throughout the engagement
Results – At A Glance
Improved BOM and ERP accuracy, minimizing downstream errors
Ensured regulatory SEMI standards through controlled workflows and audit trails
Enabled the customer to focus on new product development
Established the client's first-ever outsourced design engagement through high-quality delivery and complete process ownership
Became the client’s strategic trusted partner by successfully navigating initial concerns around data transfer and security, and building trust through process discipline and system-level alignment
Delivered 50,000+ hours of design solutions across critical subsystems
Reduced design cycle time by 20-30%, resulting in significant cost savings through accelerated project delivery
Achieved excellence across multiple performance indicators: 9.5/10 CSAT rating, first-time-right delivery, and optimized lead times
