Case Study: Leading Semiconductor Manufacturing Company achieves drastic reduction in product defects and lost profits with Sphera

Semiconductor Manufacturer Reduces Product Defects and Lost Profits Through Consistent Risk Assessment

Leading Semiconductor Manufacturing Company, a global chip maker with 20,000 employees and nearly 300 customers, faced inconsistent, homegrown risk-assessment processes across continents that hindered its goal of zero defects. The company engaged Sphera to provide a centralized Quality Risk Management solution, standardizing FMEA workflows and deploying a Global Context Matrix to replace ad-hoc Excel analyses and fragmented reporting.

Sphera implemented a consolidated operational risk system that mapped nine interrelated risk factors into a global context, reducing FMEAs from thousands to hundreds and cutting assessment workload by up to 27:1. The solution let teams quantify risks in dollar terms (identifying examples such as $100M cross-site impacts), improved global manufacturing flexibility, provided senior leadership metrics, and created the potential to avoid billions in lost profits from defective products.