Quality Engineer Product Development

Amit Chatterjee, Ph.D. **** Gardenwood Dr., San Jose, CA-95129, 408-***-****; 408-***-**** (P) *************@*****.*** mailto:*************@*****.***

OBJECTIVE: Looking for Quality/Supplier Engineering Position

CORE EXPERTISE

Knowledge of quality and reliability concepts & general manufacturing operations, ISO 9001, mechanical and electro-mechanical components/assemblies, PLC, new product introductions and product development

Specialized in vendor management, customer engagement, supplier development, supplier audits, cost reduction using new supplier certification, supplier corrective action requests, NC system management and support, contract manufacturers, continuous improvement for built to print and OEM parts.

Program management/development, NC/DMR/SCAR reduction (floor, field) of new product initiative through cross-functional team, process gap improvement & Pilot Operation

Project management experience and a solid understanding of problem solving tools including design of experiments, geometric design and tolerances, root cause analysis and statistical process control principles, gage R&R. Expert in Analysis - FMEA, PFMEA, SCAR, 5Y, 8D, Fishbone, DMAIC, SPC.

Capable to collaborate with others, supervise, self-motivated and lead the cross-functional teams in various parts of careers. Experience in handling suppliers in both Asia and USA. Real problem solver, critical thinker, active listener, well verbal and written communication skills. Published 15 patents, 100 journals papers, presented weekly basis to managements and cross-functional groups, suppliers, customers.

Strong technical expertise in thin film development, characterization, failure analysis, and complex material processes and developed new products (n, n+1, n+2). Hands-on experience on polymer, synthesis, characterization (chemical, thermal, mechanical, surface), structural-property relationship.

Coordinator for Radar -Pilot. Participated in MRB regularly. Disposition supplier related issues to 50 SQE all over world. Analyzed supplier issue data & presented weekly, monthly, quarterly reports to management. Generated improvement plans and took actions for lean product development.

Monitored suppliers through site audits and parts audits & assessments, FAI, weekly supplier meetings, maintaining supplier scorecards, risk analysis, SCAR, NCs, systemic SCARs, QMR, F23, F29 charts and PIP.

PROFESSIONAL EXPERIENCE 2010–April 2017 Applied Materials Inc, Santa Clara, CA.

Supplier Quality Engineer, Sr.

Coordinator for Pilot Radar System. Managed and supported NPI production supplier’s issues for Pilot Line daily basis. Attend MRB meetings, distributed day to day supplier issues to a team of 50 SQE/SE and managed progresses, analyzed data, created reports and updated status to management weekly, monthly and quarterly basis. Developed strategies & reduced NC by 22% over a year.

Developed supplier repeat issue, charge back program, DMR execution and reversal processes. Located gap in supplier quality process and improved production process using TrackWise, Quickbase, team center, SAP tools for lean product development and saved production cost by 7%.

Audited supplier production control and quality programs, identified non-conformance and corrected them through DMR/SCAR/8D effort for current and future products. On-site managed suppliers (4 suppliers). Qualified methods including gauges, inspection equipment, fixtures & automation. Established measurement correlation between manufacturing sites and reduced NC by 6%.

Analyzed the leak issue for ESC stacks and assemblies (mechanical and electromechanical assemble). Examined CAD drawing with DEA, ME. NPME, supplier and customers to evaluate components and sub-assemblies for designing failure. Established the RC using fish-bone tool. Implemented the CA and preventative actions for similar types of assemblies. Stop production failure at customer sites and saved 11% over-head costs.

Performed quarterly supplier audits, QMR and assessments of 4 suppliers to recognize the supplier status, capabilities, in accordance with established plans to ensure continued supplier conformance to AMAT quality system requirements.

Led project to analyze the external SCAR and 8D reports with internal customers for continuous improvement of released products. Improved manufacturing processes and reduced non-conformance of released products by 14%.

Initiated systematic supplier development and QPPM reduction projects. Reviewed QMS, PQP, PQR, QMR, F-23, part audit, suppliers audit and decreased QPPM by 19%.

Established SPC plans and controls for suppliers (machining, Quartz, polymer, sheet metal, assemble, electrical). Developed continuous improvement techniques, reduced gap variability, enhanced process control and improved SPC from 54% to 16%.

Led the data analysis for supplier issues, identified gap and implemented process improvements, established systemic training program for key suppliers, and established internal process for awareness of the supplier quality function to internal business units and pilot department. Suppliers NC was reduced to 38% for NPI products

Technical Staff, New Film Group, Applied Materials, Santa Clara, CA

Developed modern CVD technology for dielectric and polymer coating for n, n+1 and n+2 products with different platforms (Producers, Centura, Xgen). Established: novel CVD resists for EUV technology, polymer air-gap film and reduced dielectric constant from 2.3 to 1.7.

Set-up an advanced laboratory for polymer and dielectric deposition & etch. Used PECVD, TCVD, iCVD, FCVD, LPCVD, HDP systems and established BKM for chamber cleaning & coating processes, saved 11% processing time, improved uniformity, defect and yield by 6%.

Technical lead for development of thin film stacks by PECVD for VNAND memory applications. Improve uniformity, layer to layer variation and throughput 3%.

Gentex Corporation, Carbondale, PA; Corporate Research Scientist/Senior Composite Engineer 2007-2009

Developed company technology strategy and work with suppliers for future generation products. Implemented plans, qualified & managed suppliers and reached the target (17%) for next generation products.

Technical led for CVD/dip coating for smart visor with suppliers. Established 2-micron thin film with vender and resolved the clouding issue, improved revenue by 11%.

Technical team leader for polymer composite Smart Helmet team (20+ of engineers, scientists, and marketing personnel). Developed smart helmet and earned million dollar market.

Modified multi-layers pre-pregging, laminating, molding techniques and processes for Kevlar-phenolic helmet production with suppliers. Saved 9% production cost for the company.

NMRL, Mumbai, India, Depute Director, Scientist “E” 2006-2007

University of Delaware- Center for Composites Materials, USA 2001-2006

National Institute for Environmental Studies, Japan, Researcher 1998-2001

Karl –Franzens University Institute of Chemistry, Graz, Austria, Visiting Scientist 1996-1998

SGS India Limited, Calcutta, India, Laboratory Manager 1995

Jadavpur University, Calcutta, India, Assistant Professor, Department of Printing Technology 1990-1995

Education

Ph.D. Chemical Science, Jadavpur University.

PROFESSIONAL SKILLS

Chemical/Surface Analysis: SEM, TEM, FTIR, Ramon, ICPMS, ICP, LAMS, GCMS, GC, HPLC, MIPMS, TGA, TGAMS, DSC, DEA, AFM, XPS, EDX, Cone calorimeter, AAS, AES, UV-VIS, XRF, Rheology, cone calorimeter.

Mechanical/Failure Analysis: Tension, compression, SBS, Fracture toughness, DMA, DILA, OHC, OHT, PEEL Test, Optical and electrical measurements, surface roughness, CNC, flatness, parallelism.

Molding: VARTM, RTM, Autoclave, Compression (match metal, bladder, hand layup), lamination, injection, filament welding, Elevated temperature VARTM, Smart molding, Compounding using Double Arm Mixers, Single and Twin Screw Extruders, Ram Extruders, Rolling Mills, Machining, Joining and Plating.

Coating: Knife over roll (horizontal and vertical)

Reliability: Mech. vibration and shock, drop test, TC, latch-up.

Thin film deposition: AMAT Endura (PVD - RF and DC magnetron sputtering), AMAT Centura (PECVD/CVD) and ALD (thermal and Plasma based systems).

Geometric Drawing and Tolerance (GD and T).

Computer skills : Microsoft Excel, Power point, numerical algorithms and data analysis

Programming : Basic, FORTRAN, C, C++

Packages : MATLAB, Origin, Sigma Plot, JMP, QuickBase. TrackWise, Minitab

Fibers/Composites: Glass, Carbon, Kevlar, Twaron, Spectra, Dyneema, M5, hybrid fibers, Caron-epoxy; Carbon-VE; Carbon-BMI, phenolic-Kevlar, Glass/Epoxy/VE/BMI prepregs and composites, Single Fiber Composites, Unidirectional multi-fibers Composites

Resins/Polymers : Formulation, synthesis and characterization of resins (Styrene, PE, PP, Acrylic, Epoxy, BMI, Urethane, PTFE, PET, PBT, Polyester, phenolic, Polysiloxcine and Silicones, VE, Cyano Ester, Polyimide, MMA, PMMA, carbon BD, PC, PEEK)

Patents & Publications: 15 patents (published/filed) and ~100 publications.

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