Temasek sold Chartered Semiconductor and now semiconductor business is booming
Semiconductors are 'cool' again: GlobalFoundries CEO
With his industry in a sweet spot amid proliferating chip demand, Thomas Caulfield is bullish about attracting talent.
Dr Caulfield, CEO of GlobalFoundries, has set the firm a frenetic pace to match supply to the demand. ST PHOTO: GIN TAY
Ravi Velloor
Associate Editor
Aug 1, 2022
SINGAPORE - These are glory days for semiconductors, an industry that shot into global focus after supply chain disruptions during the pandemic and the attempts to decouple technologically from China highlighted how strategic the sector is to the resilience of major powers.
On Thursday, the US House of Representatives passed 243-187 a US$280 billion (S$386.4 billion) Bill aimed at boosting America's semiconductor manufacturing and competitiveness with China.
The Chips and Science Act of 2022 will spend US$53 billion on direct financial assistance to construct and expand microchip manufacturing facilities. It adds another US$24 billion in tax incentives and so forth.
"It is a strategic policy," says GlobalFoundries (GF) chief executive officer Thomas Caulfield. "I don't think anyone doubts that semiconductors are at the heart of the global economy and so it means supply chain security, economic security and sovereign security. For GF, it is not a matter of whether we will add to our US footprint, but when, and how fast. The Chips Bill will allow us to accelerate our plans."
Separately, Japan is poised to announce an R&D centre for next-generation 2-nanometre chips by the year end under a partnership with the United States in an effort to cement the supply chain and reduce dependence on Taiwan, over which superpower tensions are rising.
For the 63-year-old Dr Caulfield, whose microchips connect every cellphone in the world to a telecoms tower - if it is a 5G-enabled phone, you could even bet its chip was made in Singapore - all this excitement adds to the feeling of his industry being in a sweet spot.
"For the longest time, we were a compute-centric industry," he says. "Our growth cycles were linked to the release of Windows (software), or new x86 processors. Since the advent of the smartphone, we've now had the singularity of device and we can communicate, connect and control everything in our lives. That's spawned a whole new generation of use cases."
This proliferating demand for chips was slated to outstrip supply around 2024, but the pandemic accelerated the digital transformation. Meanwhile, supply chain issues around microchips that cost a few dollars were holding up production of US$50,000 cars and other goods.
Feature-rich chips are needed everywhere - into the embedded memory for security, Radio Frequency (RF) for connectivity, higher voltage for drive displays, and to help with precision battery management in cars. GF draws half its revenue from smart mobile devices across a range of applications.
Certainly, the firm, under Dr Caulfield, has set itself a frenetic pace to match supply to the demand.
Last week, it got permission from local officials to build a US$6 billion chip factory in Saratoga County, upstate New York, that will supply chips to car, smartphone and refrigerator makers.
Earlier this month, GF, which had earlier said it would focus manufacturing in Singapore, Germany and its US home, announced a joint venture with ST Microelectronics of Switzerland to build a jointly operated 300mm semiconductor manufacturing facility adjacent to ST's existing 300mm facility in Crolles, France.
The plant, slated to start production in 2026, will produce 620,000 300mm-thick wafers a year. Each wafer contains thousands of microchips. GF will get 58 per cent of the product.
This came after the European Commission in February adopted the European Chips Act to provide a total of up to €45 billion (S$63.4 billion) to support chip-related investments. France has reportedly agreed to invest "substantially" in the Crolles plant.
In June, GF, which manufactures semiconductors designed by the likes of Advanced Micro Devices (AMD) and Qualcomm, announced it would invest approximately $4 billion to expand its Singapore campus as part of the company's overall plan to grow its global manufacturing footprint and capacity.
From 700,000 wafers a year of 300mm capacity, GF will add 450,000 in phase-one expansion. Singapore will see two more expansions over the next decade involving some $8 billion investment.
Moore's law
The demand for wafers is so vast that old shibboleths are being recast. The chip industry used to be centred on Moore's Law, which held that the number of transistors in an integrated circuit doubles every two years.
Today, says Dr Caulfield, we are in a "more than Moore's" environment. Of the several elements of Moore's Law, the matter of lower cost per transistor ended around where the chips reached 14-nanometre sizes. Now, as technology moves towards the low single-digit nanometre, the transistor cost rises - so there is little to no cost advantage in going down that road.
Chips with lower nanometres are considered more advanced.
As for speed, you aren't really getting faster performance with each generation of the advanced chips.
What's left then is less power used per transistor, critical for applications that use millions of transistors.
"Moore's Law today is more of an economic model than a technology model," he says.
This is why GF chooses, as a matter of practical good sense, to not chase the 2-nanometre chips, and is happy in the 12-nanometre space, or even older ones.
"We are playing in a Total Addressable Market that will grow to US$150 billion. Analysts are projecting GF revenue this year at US$8 billion. We have plenty of market head room to play where we can create value for our customers."
GF is substantially owned by Mubadala Investment Co, a sovereign wealth fund owned by the United Arab Emirates, which has assets under management of US$284 billion worldwide. GF was created after the technology, development and manufacturing capabilities of chipmaker AMD were hived off in 2009.
The new owners quickly set about building global scale, initially by buying Singapore's Chartered Semiconductor Manufacturing, then more assets from IBM, Dr Caulfield's former company.
By 2018, it had global scale and handed the CEO position to Dr Caulfield. Last October, he led it to a successful share sale, pricing the shares at US$47 and gathering US$2.6 billion in the process.
The stock rose 40 per cent in its first month and reached US$79 in March, but has since given up some of the gains as investors fret about a looming recession that might cause a surplus situation in chips. It was at US$51.48 at Friday's close.
"Mubadala has been incredibly supportive, insightful and has helped us turn the business around," says Dr Caulfield, of GF's principal owner. "Maybe, they were a little bit ahead of their time - never imagined we would take 12 years to get to an IPO but nonetheless they had vision and they believed in us."
Potato chips to microchips
Last year, the New York-born Dr Caulfield, whose father was a New York City fireman, moved GF's headquarters from Santa Clara, California, to Malta, New York - an area that Senate Majority Leader Chuck Schumer - who is from the state - once joked was "more famous for potato chips than computer chips".
Dr Caulfield says business considerations, not sentiment, drove the move. Malta, upstate New York, already had a nanotech R&D facility around the University of Albany that had attracted firms like AMD, IBM and Samsung.
That had created an ecosystem of suppliers. The state sought to develop the area into a manufacturing centre with a partnership model that would see it invest US$1 billion and GF coming in with US$3.2 billion. However, GF ended up investing US$14 billion to build Fab 8, its most advanced semiconductor manufacturing facility, and the economic spin-offs for the area have been tremendous.
Aside from creating 3,000 jobs, each dollar in salary drove the local economy higher because of the velocity of money.
"Any time you invest in manufacturing, and the government participates, everyone concerned gets a great economic outcome," he says. "I moved the HQ to Malta because I need to be where the pulse of the company is, and that's a manufacturing facility."
Dr Thomas Caulfield says that it is not a matter of whether we will add to our US footprint, but when, and how fast, for GlobalFoundries. ST PHOTO: GIN TAY
Some analysts have unfavourably compared GF's gross margins of 15 per cent with those achieved by the big Taiwanese chip companies like TSMC.
Dr Caulfield attributes that to the depreciation overhang from the company's hyper-investment days - which inflicts an accounting cost on the firm.
There was also a fixed cost absorption - there were sites that hadn't been fully utilised. That's changing. In Dresden, Germany, GF shipped 320,000 wafers from its Fab 1 facility in 2020. It expects this year's fourth-quarter run rate from the same facility to be 800,000 wafers.
"The confluence of depreciation falling off, filling out our fixed footprint so we get economies of scale, and then remixing our business to be more differentiated, it's going to get us to competitive margins just like our competitors."
Gross margins should touch 40 per cent by 2024-2025, he says.
I ask him about the typical CEO's perennial worry about talent.
Firms like Intel, sought after in the 1980s by engineers such as the legendary Pat Gelsinger, now its CEO, vie for top talent with companies like Google and Amazon, partly because the latter are seen as "cool".
One of the bright spots of the chip crisis is the growing awareness of how vital the sector is, he says.
"There is a real challenge for creating new talent, and attracting talent. But even for liberal arts students, tech is (now) entering the curriculum. Semiconductors are starting to become cool again!"
Fast facts
The CEO
Dr Thomas Caulfield is the president and chief executive officer of GLobalFoundries (GF). He is 63 years old.
He joined the company in 2014 as senior vice-president.
Prior to joining GF, Dr Caulfield served as president and chief operations officer (COO) at lighting technology company Soraa from May 2012 to May 2014, and as president and COO of Ausra - which offers concentrated solar power solutions for electrical power generation and industrial steam production - from 2009 to 2010.
Earlier, he was executive vice-president of sales and marketing at Novellus Systems, and spent 17 years at IBM in a variety of senior leadership roles.
Dr Caulfield has a Bachelor of Science in Physics from St Lawrence University and a bachelor's, master's and PhD in materials science and engineering from Columbia University.
A native New Yorker, Dr Caulfield and his wife have a dayfger, 28, and son, 25.
The company
GlobalFoundries is one of the world's leading semiconductor manufacturers. Its top products include chips that connect cell phones to telecoms towers and those used in cars and fridges.
Headquartered in Malta, New York, it is substantially owned by Mubadala, the investment fund of the United Arab Emirates.
GF has some 15,000 employees spread out over 14 locations in three continents. It counts more than 200 global customers and 100 partner companies.
GF reported a revenue of US$6.6 billion (S$9.1 billion) in 2021, up 36 per cent year on year, and gross margin of 15 per cent.
It has a market capitalisation of US$28 billion.