Irene Y. Tsai
Lake Oswego,OR
Summary
Metrology & EngIneerIng Manager with a Ph.D. In Polymer Science and over 20 years of experience in semiconductor manufacturing, material characterization, and lab operations. Expert in managing complex tool modules, executing instrumentation calibration, and enforcing strict regulatory compliance (ISO-9000, cGMP, FDA, OSHA). Proven track record of driving yield improvements and cost savings ($1.5M+) at major corporations like Intel. Adept at cross-site technology transfer and leading teams in high-volume manufacturing environments.
Overview
32
32
years of professional experience
Work History
Wafer Level Assembly, Grinding Module Engineer
Intel Corporation
05.2024 - 07.2025
- Operational Management: Managed the Disco grinding tool module for Through Silicon Via (TSV) routes, ensuring 100% compliance with health and safety specifications. Used Statistical Process Control (SPC) charts for process and quality controls.
- Team Leadership: Led cross-functional teams to optimize engineering workflows and enhance product development processes. Served as On-Call Engineer, resolving critical technical issues during periods of high demand to minimize equipment downtime and maintain production continuity. Mentored junior engineers and technicians, fostering skill development and knowledge sharing within the team.
- Efficiency Gains: Aligned cross-functional teams to meet tight Foveros product deadlines, boost performance and achieve impactful results.
- Vendor Relations: Collaborated with key equipment and materials suppliers to design and implement technology components.
R&D Packaging Platform Engineer
Intel Corporation
05.2022 - 07.2024
- Conducted pathfinding activities that enhanced the epoxy underfill process, leading to the efficient production of innovative device architectures.
- Implemented key modifications to epoxy underfill packaging equipment, boosting production efficiency and enhancing manufacturing techniques to increase new product output.
- Collaborated with key equipment and materials suppliers to design and implement crucial technology components, which resulted in 1.5 million saving and strengthened supplier partnerships.
- Conducted epoxy underfill process technology feasibility studies, leveraging state-of-the-art instruments and methodologies, which led to significant process innovations and efficiency improvements.
- Incorporated the latest industrial process and material manufacturing trends to significantly advance epoxy process development.
- Led cross-functional teams in troubleshooting various packaging design processes and ensuring minimal downtime.
Consultant/Principal Scientist in Materials Development
Menicon Singapore Pte Ltd
01.2017 - 11.2017
- Project & Materials Management: Managed the end-to-end development of surface coating materials for contact lenses, ensuring successful product alignment for the USA and Japan markets. Managed budget of $1.2 million and 3 full time employees.
- Regulatory Compliance & Data Analysis: Evaluated critical technical data and characterization results to guarantee full compliance with rigorous medical device regulatory requirements (FDA/PMDA).
- Technical Reporting: Authored comprehensive scientific reports and documentation to validate project progress and fulfill regulatory submission standards.
- Analyzed market trends to inform business strategies and drive competitive advantage.
Scientist II in Surface Technology Group
Singapore Institute of Manufacturing Technology
07.2012 - 07.2015
- Project Management: Managed cross-functional R&D teams and industrial projects for clients including Advanced First Aid Research and JMS Singapore, managing scope, budgets, and timelines for deliverables. Delivered the project ahead of schedule and reached 100% budget requirements.
- Regulatory Compliance: Evaluated coating processes for medical needles, ensuring adherence to strict FDA and cGMP regulatory standards (directly transferable to TSMC compliance requirements).
- Process Improvement: Implemented new Standard Operating Procedures (SOPs) based on metrology data that improved product quality and consistency.
- Surface Characterization: Utilized advanced metrology tools to analyze surface coatings, driving breakthroughs in application performance.
- Quality Assurance: Recommended improvements to optimize coating processes, ensuring alignment with strict regulatory compliance.
Lab Manager/Postdoctoral Researcher
University of Pennsylvania
04.2008 - 10.2010
- Lab Operations & Calibration: Managed daily lab operations, including the purchasing of supplies and calibration of metrology equipment (FTIR, Ellipsometer, AFM).
- Staff Supervision: Directly supervised and trained 5 undergraduate researchers on lab safety, equipment usage, and experimental design.
- Data Integrity: Oversaw data management and integrity for complex experiments, ensuring reproducible results for publication. Published in 3 peer reviewed articles.
Postdoctoral Researcher
Tufts University
09.2004 - 12.2005
- Supervised and guided five undergraduate students, significantly improving their research skills and leading to three successful project completions.
- Collaborated with Tufts Imaging Group to develop imaging technology on silk proteins for tissue engineering applications.
- Led 3 research project in material purchasing, testing, and reporting results, resulting in enhanced material efficiency and better decision-making for biomedical applications.
- Submitted and published 3 peer-reviewed article and a book chapter, advancing the field of biomedical engineering.
- Produced, assessed, and critiqued scientific papers, delivering insights that enhanced research quality and clarity.
Researcher in Thomas P. Russell's Group
University of Massachusetts
09.2000 - 05.2004
- Carried out Physical Vapor Deposition on silicon wafers to deposit Gold or Chromium and various other coating processes such spin coating, drawdown coating and etching technology.
- Engineered gradient coatings with diblock copolymers and homopolymer blends, enhancing biocompatibility and performance for specialized industrial applications.
- Analyzed large set of data using imaging analysis tool such as Image J and statistical software such as Origin.
- Collaborated with biologists on cellular behaviors on topographic surfaces using lithography and spin coating and drawdown coating techniques.
- Mentored 2 undergraduate students.
- Written, submitted and published 5 publications and 1 invited chapter in a book.
R&D Engineer in Advance Fibrous Media Group
Pall Corporation, Research and Development
04.1997 - 08.1999
- Developed and optimized biocompatible biomaterials for blood filters as well as adherence to medical devices regulatory compliance.
- Developed and modified process conditions for melt-blown process using single extruder.
- Designed the optimal die configuration to fiberize various polymers with melt-blown process. (PP, PBT, Fluoropolymer, PPS, Polyurethane, LCP and Polyketone)
- Led and innovated product development processes, resulting in three industry-leading launches that boosted market competitiveness.
- Enhanced manufacturing operations by deploying melt blown extrusion process proactively identify and resolve issues, thereby optimizing production efficiency.
- Enhanced sample accuracy and reliability by conducting lab tests with FTIR and fluorescence spectroscopy, testing equipment, and analyzing customer samples.
Quality Engineer
Bio-Medical Polymers Technology Corp.
04.1996 - 04.1998
- Reviewed, evaluated, and implemented all approved product, packaging, and process changes for medical device regulatory requirements.
- Carried out various aspects of quality control of the catheter production of medical devices for a startup company.
- Implemented various aspects of the GMP process for micro-catheter extrusion for compliance to FDA regulatory requirements.
- Collaborated in designing the die for catheter extrusion to improve quality control.
- Strengthened regulatory compliance by strategically assessing, implementing, and managing FDA GMP and ISO-9000 standards for medical device catheters.
Test Engineer in Air Control Product Group
GM, Delphi Energy & Engine Management Systems
07.1994 - 04.1996
- Expedited all aspects of the environmental testing for throttle body, including Linkage Cycle, Corrosion, Dust, Vibration, Temperature Shock, and Temperature Cycling.
- Diagnosed throttle bodies returned from the field using specialized tools, identified root causes of malfunctions, and provided actionable solutions, enhancing overall product reliability.
- Documented, reviewed, and evaluated product test procedures for QS9000/ISO9000, enhancing procedural accuracy and compliance with quality standards.
Intern in Mechanical Equipment Design Group
Air Products and Chemicals, Inc.
06.1993 - 08.1993
- Customized database to facilitate entering and querying data for various equipments.
- Performed calculations to ensure product retention for oxygen and nitrogen tanks.
- Conducted structural calculations for a pressurized vessel, ensuring compliance with safety standards.
Education
M.S., Ph.D. - Polymer Science and Engineering
University of Massachusetts
Amherst, MA01.2004
B.S. - Mechanical Engineering
Columbia University
New York05.1994
Skills
- Metrology & Characterization: AFM, XPS, FTIR, SEM, Ellipsometry, Fluorescence Spectroscopy, PVD, Plasma Etching
- Lab Management: Equipment Calibration, Preventive Maintenance (PM), Chemical Inventory, SOP Development
- Process Control: Statistical Process Control (SPC), JMP, Origin, ImageJ, Root Cause Analysis, FMEA
- Compliance & Safety: ISO-9000, QS9000, FDA cGMP, OSHA Safety Standards, NIST Traceability
- Leadership: Cross-functional Team Leadership, Vendor Management, Budgeting, Staff Training & Mentorship
Languages
Chinese (Mandarin) Conversational
Timeline
Wafer Level Assembly, Grinding Module Engineer
Intel Corporation
05.2024 - 07.2025
R&D Packaging Platform Engineer
Intel Corporation
05.2022 - 07.2024
Consultant/Principal Scientist in Materials Development
Menicon Singapore Pte Ltd
01.2017 - 11.2017
Scientist II in Surface Technology Group
Singapore Institute of Manufacturing Technology
07.2012 - 07.2015
Lab Manager/Postdoctoral Researcher
University of Pennsylvania
04.2008 - 10.2010
Postdoctoral Researcher
Tufts University
09.2004 - 12.2005
Researcher in Thomas P. Russell's Group
University of Massachusetts
09.2000 - 05.2004
R&D Engineer in Advance Fibrous Media Group
Pall Corporation, Research and Development
04.1997 - 08.1999
Quality Engineer
Bio-Medical Polymers Technology Corp.
04.1996 - 04.1998
Test Engineer in Air Control Product Group
GM, Delphi Energy & Engine Management Systems
07.1994 - 04.1996
Intern in Mechanical Equipment Design Group
Air Products and Chemicals, Inc.
06.1993 - 08.1993
B.S. - Mechanical Engineering
Columbia University
M.S., Ph.D. - Polymer Science and Engineering
University of Massachusetts