Engineer Process

MATTHEW SLADICKA

480-***-**** ********@*****.***

PROFESSIONAL SUMMARY

A ten year Senior Engineer with proven track record of technical experience ranging from sustaining,

technical support, new product development, and quality improvement. A certified six sigma black

belt highly experienced in project management, development and continuous improvement methods.

A Strong problem solver with ability to adapt to change and new challenges. Areas of expertise

includes:

PROFESSIONAL EXPERIENCE

ASQ SIX SIGMA BLACK BELT CERTIFICATION: Freescale Semiconductor Project work

• Led a team using Six Sigma DMAIC methodology in making a major front end process change

that reduced output parameter variation by 85%, reduced defectivity failures by 40%, increased

yield by 2%, and reduced process time by 30%. Project results had an estimated annual saving

of $79,000/year not including the yield gain. Received Freescale Technical Excellence Award for

the Most Significant Technical Contribution in Q3 2004.

• Managed a cross functional team in utilizing DMAIC methodology to isolate and eliminate an

overlay defect that was masking out critical killer defects at an inline inspection point.

• Demonstrated DOE methodologies through performing a half fraction 5 factor 2 level screening

experiment on flat films monitoring four output variables that led to a 30% reduction in variation

for output variables.

• Maintained Statistic Process Control and FMEAs for Oxide and Poly Etch processes.

• Demonstrated Multi-vari Analysis (MVA) statistical techniques by identifying sources of variation

for a critical output parameter.

FREESCALE SEMICONDUCTOR (FORMERLY MOTOROLA), Chandler, Arizona 1998 – 2009

Yield Enhancement Module Engineer 2006 – 2009

Maintained baseline defectivity levels for the gate module by implementing SPC controlled on-

product KLA monitors to detect defect excursions. Reduced baseline defectivity levels by managing

cross-functional continuous improvement teams. Set defectivity testing requirements for all

Corrective Action Board engineering changes that occur in the gate process module.

• Isolated root cause for defect excursions, applied containment, dispositioned non-conforming

product in a Material Review Board, and worked with responsible process engineering

department to identify short term and long term actions to prevent repeat occurrences.

• Identified continuous improvement projects and managed cross functional teams to lower

baseline defectivity. Some projects reduced defectivity at an inspection point by as much as

50% and increased baseline yield by more than 5%.

• Reviewed Failure Analysis Reports to assist Quality department in isolating root cause for

product returns so preventative actions could be implemented.

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• Trained Yield Enhancement Team on new software which contains CAD renderings of Photo

Reticles. Use of software helped identify several design mistakes which was attributed to as

much as 15% yield loss.

Senior Process Engineer 2001 – 2006

Sustained etch equipment in a manufacturing environment through utilization of SPC methods to

control and improve etch processes. Worked with device engineering and yield enhancement to

improve the Poly etch and Front End Oxide (FOX) etch processes to achieve industry benchmark

yields. Optimized etch tool and process performance for reduced variation, improved process

capability and improved product yield.

• Qualified new AMAT DPS poly etch chambers and released into production by ensuring that

outputs met Purchase Agreement requirements and had no adverse effect on parametric or

yield. Implemented a new equipment modification which increased throughput by 20%.

• Developed a methodology for monitoring and controlling etch tool defectivity performance by

using an on-product defectivity monitor resulting in a savings greater than $100K/year. The

method resulted in quick root cause identification for tool and integration defectivity issues and

was later propagated across all Process Engineering Departments.

• Qualified a modified capture ring on DPS Poly Chambers which eliminated backside helium faults

and had a savings of $250K/year due to inline scrap reduction.

• Utilizing DMAIC Methodology identified interactions between different FOX etch processes and

separated them to eliminate process interaction variation in process output parameters.

• Utilized and created Failure Detection Control Models to detect tool performance deviations and

automatically shut equipment down as the deviation happens.

• Created, maintained, and documented changes in all Poly and FOX etch specifications.

• Mentored new engineers and process technicians in troubleshooting, risk assessment, SPC and

process dynamics.

Process Integration Engineer 1998 – 2001

Responsible for development of characterized etch processes to be transferred into manufacturing

factories. Required to design experiments, analyze data, solve problems, oversee daily process

performance and ensure successful transfer.

• Developed MIM Oxide Etch Process using a Screening Experiment and a Robust Design

Experiment optimizing four separate output parameters to meet design requirements.

• Completed development, characterization and transfer of 0.35 micron HBT CMOS process, MIM

Process, and 0.5 micron BiCMOS etch process to a manufacturing factory.

• Developed processes, procured equipment, and oversaw conversion of eight inch Si equipment

for six inch GaAs production.

• Designed an interfab communication tool making use of the Motorola’s intranet, Core directory

and Oracle database that got propagated to all Motorola Semiconductor Factories Worldwide.

• Installed Gasonics L3510 and a LAM4420 and through testing confirmed that the tool

performance fulfilled the purchase agreement requirements before releasing to manufacturing.

• Mentored intern on a broad range of semiconductor projects resulting in her accepting a full time

process engineering position.

EDUCATION

Bachelor of Science, Chemical Engineering

North Carolina State University, Raleigh, North Carolina

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PROFESSIONAL DEVELOPMENT

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