Excessive Costs from High Water Usage and Chemical Management in Process Control

$2,400,000 to $3,650,000 annually per fab facility from excess water procurement (based on 10M gallons/day ultrapure water consumption at industrial rates) plus $400,000-$800,000 in waste from poor chemical management and unnecessary supplies due to lack of visibility, plus $150,000-$300,000 in emergency maintenance costs from preventable equipment failures • $300,000–$1,000,000 per year per fab in avoidable municipal/UPW water spend and wasted chemicals due to over-purging, excessive rinses, and inefficient scrubber/tool settings, plus $100,000–$500,000 per year in rush freight, premium maintenance, and lost margin from line slowdowns tied to unplanned recalibration and bath change events. • $600K-$1.8M annually from unplanned water line downtime (2-8 hour stops × $150K-$300K/hour production loss); $200K-$500K in emergency chemical waste disposal surcharges; $400K-$1.2M in preventable water quality incidents requiring re-processing

EHS and process teams manually reconcile water and chemical usage by exporting logs from facility SCADA and tool historians into Excel, then cross-checking with supplier PDFs, paper logs, and email/WhatsApp updates from maintenance to decide when to adjust recipes, purge baths, or schedule rush deliveries. • Manual daily checklists on paper; WhatsApp notifications to maintenance team when water pressure drops; memory-based understanding of filter change intervals; ad-hoc communication with chemical waste disposal vendors • Manual water consumption logs in Excel spreadsheets; WhatsApp alerts for tank levels; Paper-based chemical inventory tracking; Memory-based process recalibration schedules; Email chains for equipment maintenance requests; Verbal communication between shifts on water pressure anomalies