Samsung Foundary Struggles with Low Yields in 3nm GAA Process as TSMC Dominates with 62.3% Market Share in Q2 2024

Samsung Foundry faces challenges with low yields in its 3nm Gate-All-Around (GAA) process, losing ground to TSMC, which dominates the global foundry market with a 62.3% share in Q2 2024.

Introduction

Samsung Foundry is facing significant hurdles as its production yields for the 3nm Gate-All-Around (GAA) second-generation process falls below expectations. This setback has hindered the company’s ability to attract major clients and maintain competitiveness in a market increasingly dominated by its primary rival, TSMC.

Samsung’s foundry division, once considered a leading player in the semiconductor landscape, now faces daunting challenges that threaten its market position.The company is experiencing low yields from its 3nm GAA process, which limits its ability to secure contracts with major technology firms. Meanwhile, TSMC, a formidable competitor, continues to capture a significant share of the global foundry market. As Samsung navigates these issues, discussions surrounding the potential spinoff of its foundry business have gained traction.

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Key Points Overview

  1. Yield Challenges: Samsung GAA 3nm process has struggled with low production yields, impacting its ability to secure clients.
  2. Market Competition: TSMC leads the global foundry market with a 62.3% share in Q2 2024, while Samsung captures only 11.5%.
  3. High-Profile Client Losses: Major tech firms, including Nvidia and Apple, have partnered with TSMC, leaving Samsung at a disadvantage.
  4. Financial Implications: Analysts predict Samsung could face substantial losses in its non-memory segment, impacting overall profitability.
  5. Calls for Strategic Change: There is increasing pressure for Samsung to consider spinning off its foundry business and pursue a U.S. listing.

Yield Challenges: The Struggle with 3nm GAA Process

Samsung 3nm GAA second-generation process aimed to position the company at the forefront of semiconductor manufacturing.

However, low production yields have plagued its efforts. According to recent reports from Business Korea, this instability has made it difficult for Samsung to attract high-profile clients that are essential for its growth.

The GAA architecture was supposed to provide improved performance and power efficiency compared to traditional FinFET technology.

However, the complexities involved in its production have led to inconsistent outcomes, raising concerns among potential customers about the reliability of Samsung’s manufacturing capabilities.

Market Competition: TSMC’s Dominance

The semiconductor foundry market remains fiercely competitive, with TSMC (Taiwan Semiconductor Manufacturing Company) firmly entrenched as the leader.

As of Q2 2024, TSMC held a commanding 62.3% market share, while Samsung lagged behind with just 11.5%.

This gap in market presence poses significant challenges for Samsung, especially when major players like Nvidia and Apple are increasingly opting to work with TSMC for their chip manufacturing needs.

The reasons for TSMC’s success are multifaceted. The company has consistently invested in advanced technologies and has established strong relationships with key clients.

Furthermore, TSMC’s focus on maximizing production efficiency and minimizing yield issues has made it a go-to partner for many tech giants.

In contrast, Samsung’s difficulties with its 3nm process have contributed to its struggle to secure similar partnerships.

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High-Profile Client Losses

Samsung’s inability to deliver reliable yields has resulted in the loss of significant contracts. Industry insiders report that many leading tech companies are hesitant to rely on Samsung for their chip manufacturing.

Companies like Nvidia and Apple have publicly favored TSMC for their cutting-edge products, further isolating Samsung in the competitive landscape.

The repercussions of these client losses are severe. Without contracts from major players, Samsung’s foundry division risks stagnation, leading to reduced revenue and market relevance.

As the demand for advanced chips continues to grow, the pressure is on Samsung to address its yield challenges swiftly.

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Financial Implications: Projected Losses

The financial impact of these yield issues and client losses cannot be understated. Analysts predict that Samsung could incur a staggering 500 billion won (approximately $385 million) loss in its non-memory segment, which includes the foundry and system LSI businesses.

This projection comes as the company prepares to announce its third-quarter results, which are likely to reflect these challenges.

This financial strain not only affects Samsung’s bottom line but also raises concerns among investors.

As the company grapples with declining profitability, stakeholders may begin to question its strategic direction and long-term viability in the foundry market.

Calls for Strategic Change: The Push for a Spinoff

As Samsung continues to navigate its challenges, there is increasing pressure from industry experts and stakeholders to consider a strategic overhaul.

Recent reports suggest that Samsung Securities has recommended spinning off the foundry division and pursuing a U.S. listing.

This proposal aims to streamline operations and enhance the division’s focus on competing effectively in the global market.

The push for a spinoff is partly influenced by Intel’s recent decision to transform its own foundry division into a wholly owned subsidiary.

By establishing its own board of directors, Intel aims to prioritize growth and operational efficiency in a rapidly evolving industry.

Following this trend, Samsung’s potential spinoff could allow the company to reallocate resources more effectively and improve its competitiveness.

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Conclusion: A Crucial Crossroads for Samsung Foundry

Samsung Foundry stands at a critical juncture as it confronts significant challenges in production yields, client retention, and financial stability.

With TSMC continuing to dominate the market and high-profile clients gravitating towards its services, Samsung must take decisive action to reclaim its competitive edge.

The ongoing yield struggles of its 3nm GAA process highlight the urgent need for improvement.

Furthermore, external calls for a strategic spinoff and U.S. listing signal that stakeholders are looking for innovative solutions to revitalize the foundry business.

As Samsung prepares for its upcoming Foundry Forum and quarterly results announcement, all eyes will be on the company’s strategies for addressing its pressing challenges.

The decisions made in the coming months will shape the future of Samsung Foundry and its place in the global semiconductor landscape.

Kumar Priyadarshi
Kumar Priyadarshi

Kumar Joined IISER Pune after qualifying IIT-JEE in 2012. In his 5th year, he travelled to Singapore for his master’s thesis which yielded a Research Paper in ACS Nano. Kumar Joined Global Foundries as a process Engineer in Singapore working at 40 nm Process node. Working as a scientist at IIT Bombay as Senior Scientist, Kumar Led the team which built India’s 1st Memory Chip with Semiconductor Lab (SCL).

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