Current Security Challenges in Semiconductor Manufacturing and Effective Countermeasures

Introduction: Why malware countermeasures are now critical in semiconductor manufacturing

Semiconductors are a strategic resource at the heart of countless products—from smartphones and automobiles to industrial equipment. Amid ongoing global semiconductor shortages and rising geopolitical tensions, ensuring stable operation of manufacturing lines has become a matter of national importance.

However, many semiconductor production environments remain air-gapped or rely on standalone systems, making it impractical to deploy conventional cloud-based security solutions. As a result, the risk of malware infiltration via USB flash drives or maintenance PCs has emerged as a serious and growing threat.

Figure 1: The risk of malware infection via USB flash drives is a constant concern for industries that don’t have cloud-based security solutions. (Image source: Hagiwara Solutions)

Impact and financial losses caused by malware infections

Malware can cost companies significant losses. For example:

• Taiwan – TSMC (2018): A malware infection through the supply chain halted parts of the production line. The estimated financial damage was approximately USD 250 million. (Source: Bloomberg)
• Germany – Manufacturing Sector (2020): A wave of ransomware attacks led to multiple plant shutdowns, with the average loss per incident estimated at EUR 17 million. (Source: Allianz Risk Barometer)
• Japan (2023): According to a report by IPA, cyber incidents in the manufacturing sector increased by approximately 1.5 times compared to the previous year. (Source: IPA White Paper)
• United States - Colonial Pipeline Incident (2021): A ransomware attack on critical infrastructure disrupted fuel distribution nationwide. (Source: FBI)
• Statista Report (2025): The manufacturing sector ranked among the most frequently targeted industries worldwide, according to a 2025 Statista report, the manufacturing sector accounted for 26% of all reported cyberattacks in 2024. (Source: Statista)

Table 1: Distribution of cyberattack incidents in companies worldwide (2019 – 2024), by industry. (Source: Statista)

Table 1 shows the percentage distribution of cyberattack incidents across different industries worldwide from 2019 to 2024. According to the 2024 data:

• The manufacturing sector ranked highest, accounting for 26% of all reported incidents
• The finance and insurance sector followed at 23%
• The professional, business, and consumer services sector came in third at 18%

Notably, the manufacturing sector has shown steady growth—from just 8% in 2019 to 26% in 2024. This trend highlights the sector’s increasing vulnerability as a target, driven by accelerated digital transformation and the growing complexity of global supply chains.

Figure 2: Malware infections in the manufacturing sector are increasing. (Image source: Hagiwara solutions)

Unique security challenges in semiconductor manufacturing environments

Presence of offline systems

Semiconductor manufacturing equipment often operates in isolated environments, separated from external networks. As a result, cloud-based or internet-connected antivirus solutions are generally not applicable or usable in such settings.

Risks during maintenance and system updates

There have been numerous cases where laptops or USB flash drives brought in by external vendors became sources of malware infections. Standalone systems are particularly vulnerable, as delayed detection increases the risk of widespread impact.

Security requirements under SEMI standards

In 2022, the Semiconductor Equipment and Materials International (SEMI) issued two key standards—SEMI E187 and SEMI E188—that mandate malware protection responsibilities for both equipment manufacturers and semiconductor fabs. These standards emphasize the need for robust countermeasures against malware throughout the semiconductor supply chain.

What is SEMI?

Overview and role of SEMI

SEMI (Semiconductor Equipment and Materials International) is a global industry association representing the semiconductor and electronics manufacturing supply chain. Through the development of international SEMI Standards, global exhibitions such as SEMICON, statistical research, and workforce development initiatives, SEMI supports industrial progress and technological innovation.

With regional offices worldwide, SEMI promotes collaboration among its member companies and the sharing of best practices. In recent years, the organization has placed increased emphasis on cyber resilience, launching cybersecurity standards such as SEMI E187 and E188 and fostering specialized communities like SMCC (Smart Manufacturing Community Consortium).

Purpose and background

SEMI was established to address cross-industry challenges in the semiconductor sector, such as interoperability, safety, quality, and procurement standardization across equipment manufacturers, material suppliers, and fabs. By leveraging its extensive global membership network, SEMI enhances efficiency and transparency across the supply chain through standardization, global exhibitions, and talent development.

Since 2018, in response to escalating cybersecurity risks, SEMI has accelerated its efforts in this domain. This includes publishing cybersecurity-related standards such as E187/E188 and forming cross-sectoral initiatives like SMCC.

Benefits of SEMI guidelines

• Global Trust and Compliance: Companies can demonstrate compliance with globally recognized standards for quality, safety, and interoperability—strengthening their credibility in international markets.
• Increased Business Opportunities: Many leading fab and OEMs require SEMI compliance as a condition for procurement. Meeting these standards improves eligibility for tenders and contracts.
• Faster Equipment Integration: Adherence to common specifications facilitates smoother acceptance testing and system integration, reducing deployment time and minimizing errors.
• Long-Term Cost Reduction: Reduces risks of redesigns and retrofits caused by specification mismatches, thereby lowering maintenance and operational costs.
• Simplified Regulatory and Audit Readiness: Compliance with safety, environmental, and cybersecurity standards helps companies better prepare for regulatory inspections and audits.

Overview and Significance of SEMI E187 and E188

SEMI E187 (Specification for Cybersecurity of Fab Equipment)

• Purpose: Ensure cybersecurity of semiconductor manufacturing equipment prior to shipment
• Key Requirements:
  • Pre-shipment malware scanning
  • Vulnerability assessment
  • Standardized security configurations
• Background: Aims to guarantee that equipment arrives at the customer site free from malware, minimizing downstream contamination risks.

SEMI E188 (Specification for Malware-Free Equipment Integration)

• Purpose: Prevent malware infection during equipment installation and maintenance at production sites
• Key Requirements:
  • Mandatory malware checks before and after maintenance activities
  • Scanning of all external media (e.g., USB drives)
  • Logging and reporting to ensure traceability and accountability
• Background: Designed to protect fab operations from threats introduced through external vendors or maintenance activities.

Why this matters

Semiconductor manufacturing is a 24/7 operation, and even a single hour of downtime can result in major losses. These SEMI standards represent the minimum baseline for cybersecurity readiness. Failure to comply not only increases operational risks but can also lead to a loss of credibility in global business transactions.

Alignment between SEMI standards and Vaccine USB3

Vaccine USB3 (Figure 3) from Hagiwara Solutions is a malware scanning tool designed for use on offline or standalone systems typically found in production plants, research laboratories, and medical institutions. It enables on-demand malware scanning without the need for prior software installation or configuration changes on the target system.

Figure 3: Hagiwara Solutions’ Vaccine USB3 is a standalone malware scanning tool that allows for scanning without prior software installation or configuration changes. (Image source: Hagiwara Solutions)

This unique capability allows Vaccine USB3 to contribute directly to compliance with SEMI standards, particularly in the areas shown in Table 2.

Table 2: How Vaccine USB contributes to SEMI standard compliance.

Key Features of Vaccine USB3 and its contribution to SEMI standard compliance

No installation required

Vaccine USB3 does not require any software installation or system configuration prior to use. Users simply plug the device into a target system and launch the built-in scanning software stored on the USB itself. This enables malware detection, isolation, and removal directly from the USB device.

Scan results are indicated via an LED system on the device (Figure 4):

• Red LED: Infection detected
• Blue LED: No malware found

Figure 4: A blue LED indicates that no malware infection has been found while a red LED identifies that malware infection is present. (Image source: Hagiwara Solutions)

Because network connectivity is not required, the tool can be operated on demand in completely offline environments. This makes it ideal for use in semiconductor manufacturing plants and critical infrastructure facilities, where systems are often air-gapped from external networks for security reasons.

Flexible licensing model

A single unit of Vaccine USB3 can be used to perform malware scans on multiple endpoints. This makes it a cost-effective solution for organizations managing large numbers of offline or standalone devices.

High-precision and high-speed scanning

The latest malware definitions can be preloaded onto the Vaccine USB3 by connecting it to a PC with internet access. Using updated definitions, the tool can accurately detect both known and unknown malware. To enhance scanning efficiency, users can configure various modes such as:

• Differential scanning (scan only changes)
• Timer-based scanning
• Targeted scan scope settings

These flexible scanning options help adapt the tool to site-specific operational requirements.

Logging functionality

Scan results are automatically stored as log files on the Vaccine USB3 device. Additionally, the tool can record asset information from the scanned system, including hardware configuration and installed software. This dual-logging feature allows organizations to perform basic asset management of standalone systems— a domain that is often difficult to manage in offline environments.

Reporting capabilities: strong support for SEMI standard compliance

Automatic Generation:

Upon completion of a scan, Vaccine USB3 automatically generates a report summarizing the inspection results.

Report Contents:

• Date and time of the scan
• Target system information (host name, OS version, etc.)
• Details of detected malware (name, type, and handling result)
• Version of the malware definition file used
• Summary of the scan result (Safe / Action Required)

Format:

Reports can be saved in PDF format or other printable file types, enabling flexible documentation.

Relation to SEMI Standards:

• SEMI E187: Reports can be attached as proof of pre-shipment inspection, supporting accountability to customers and regulatory auditors.
• SEMI E188: Reports can be archived as maintenance records, useful for internal audits and cybersecurity evaluations in the factory environment.

Benefits

• Streamlined traceability management (supporting both paper-based and digital formats)
• Enhanced accountability to customers and auditors
• Easier information sharing between operators
• Enables standardization of security requirements in vendor contracts by mandating report submission

Sample Vaccine USB3 malware diagnostic report (Figure 5)

Figure 5: Example of a Vaccine USB3 malware diagnostic report. (Image source: Hagiwara Solutions)

Benefits of Adoption: Perspectives from equipment manufacturers and fabs

Equipment manufacturers

• Fulfill SEMI E187 requirements during pre-shipment inspections, enhancing customer trust
• Reduce post-delivery issues, resulting in lower support and warranty costs
• Improve competitiveness in international markets by demonstrating compliance with global standards

Semiconductor fabs

• Minimize the risk of infection during maintenance activities
• Establish operational frameworks that comply with SEMI E188
• Reduce the likelihood of production line downtime due to malware incidents
• Standardize security requirements by incorporating report submission clauses into vendor contracts

Conclusion and recommendation for deployment

Malware protection in semiconductor manufacturing environments is no longer optional—it is essential. Vaccine USB3 offers a practical, installation-free solution that is ready for immediate use in offline environments, while also supporting compliance with SEMI E187 and E188 standards.

For both equipment manufacturers and semiconductor fab, Vaccine USB3 serves as a cost-effective, low-barrier tool to reduce cybersecurity risks—available for deployment starting with just a single unit. Deployment is simple and does not require changes to existing infrastructure. Now is the time to take a proactive step toward cybersecurity readiness. Be prepared before an incident occurs.