Self-driven, organized and detail-oriented engineer/manager working with global cross-functional teams of engineers, suppliers and customers on fast-paced projects focused on critical customer quality and top product launch issues. Deep experience across many disciplines including medical and consumer devices. Several years of hands-on practice on Six Sigma, Lean, Kaizen and other Continuous Improvement methods. Recognized subject matter expert in statistics, SPC, DOE, quality system and big data analysis.
· Identify and track main operation KPIs such as
Cost Savings: Implemented a process to reduce storage cost by 30%
Station Downtime Reduction: Lead an effort to reduce station interruption by % 20
CSAT: Created surveys to evaluate customers and operators satisfaction with an achieved goal of >80%
· Prepare and manage EFFA (Early Field Failure Analysis) by
Merging all programs into the same Universal User Interface (UUI)
Reviewing and improving contractor hiring and onboarding by enhancing the JD and training
Providing labs, offices and manpower
Hosting several crews of CMs and local FA teams
· Evaluate and forecast budget for operation team and presented to finance and upper management.
· Run weekly, monthly and 1:1 meeting with my direct reports to review tasks and R&R and achievements.
Staff Engineer/Program Manager 2016-2022
· Audited more than ten battery (cells and pack) OEMs in Asia and labs in US and lead action items
· Analyzed and correlate lab data with field battery performance using ML models and JMP
· Collaborated with AppleCare to analyze big data and predict battery future performance
· Trained cell engineers in US and Asia on six sigma and lean tools: GRR, SPC, OEE, 5S, Poke Yoke etc..
· Reduced measurement variation by more than 30% at supplier sites by developing standard procedures for novel separators films.
· Led cross functional team of engineers to integrate new processes into MEMS display devices resulting in lifetime increase from 800M contacts to 3B+ contacts
· Responsible for tool purchase exceeding $2,500,000; criteria included tool design, process capability, repeatability, cycle time and throughput
· Led thin film process development using SAM, ALD and PECVD equipment
· Monitored and managed BE SPC (process and tools)
· Trained engineers and technicians on R&D techniques, tools and process
Process Development
· Selected, bought and qualified several PECVD tools (Oerikon and AKT)
· Developed several PECVD processes for active layers (TFT and Diode) and passive layers (SiN and SiOx)
· Optimized PVD Source and Drain process and eliminate 100% of open and cracking data lines
Lean Manufacturing Leader
· Launched a continuous improvement program using six sigma methodology, hiring, training, and managing 12 team members
· Used lean manufacturing tools to improve yield and cycle time
Reviewed weekly move, tool performance, SPC charts and took actions when necessary
Led brainstorming and FMEA sessions and performed data analysis for yield improvement and process optimization
Investigated and implemented corrective and preventive plans (CAPA) as appropriate
· Selected and qualified new gas suppliers for all plasma process tools resulting on 30% cost saving
· Developed a recycle plan for test plates (deposition-etch-deposition) resulting on 25% cost saving
· Developed, optimized novel low k materials using PECVD VECTOR 300 mm tool and performed successful (live) demos for customers such as IBM and Intel
· Assisted Intel team in trouble shooting process issues such as k value-shift, uniformity, particles using VECTOR 300 mm tool.