Engineer Reliability and Quality

SAM ZHANG, PhD

510-***-**** (C), ***********@*****.***, 43742 Abeloe Terrace, Fremont, CA 94539

SR RELIABILITY OR QUALITY ENGINEER

QUALIFICATIONS:

Over 20 year professional experiences in reliability/quality engineering, process development, project management and scientific research.

ASQ: Certified Reliability Engineer

Certified: ISO Internal Auditor

Skills:

Quality tools, FMEA, PACA, RMA, SPC, DOE and Gage R&R

Reliability lab and FA lab layout, equipment selection, setup, and operation

Reliability life and qualification tests, HALT, HTOL, Op TC, Op Shock & Vibe, EMC/EMI and ORT

Reliability Modeling for MTBF, Reliability Growth, bottom-up and top-down apportionments

Hands-on failure analysis: thermal, electrical, ESD, mechanical and optical failures

Reliability Software tools, ReliaSoft, BlockSim, Weibull++, JMP, and Monte Carlo

Quality/supplier/ISO auditing, and supplier quality management and improvement

Project management, new product introduction (NPI)

Strong verbal, written and presentation skills, and interpersonal skills

Highly motivated, honest and open, team player and hands-on, analytical, eager for challenges.

Extensive knowledge in: various industrial and military standards Telcordia, ISO, MIL, IPC, EMC/EMI, JEDEC, ANSI

Status: US Citizen

MAJOR ACCOMPLISHMENTS:

Identified top 3 failures of video wall products and feedback for design changes and improved product quality and reliability performance

Completed 30 qualification tests and identified critical failures and made key contributions for product quality and reliability improvements

Reduced RMA backlog from 700+ units to less than 100 in a short time

Saved company for $6 millions from recalls by solving quality/reliability issues

Reduced customer return rate from 15% to 1% within 9 months

Managed NPI project and launched mass production for a $20 million revenue product

Cost reduction of $1.5 million (hard money) by introducing new vendor for laser texture tools

Invented laser texture process on glass substrate independent of IBM

One of three world-wide successful pioneers on developing high Tc RF SQUID devices

Award winner (1st place, valued $3600) for Shanghai Outstanding Scientific Research

14 publications in national and international scientific and engineering journals

PROFESSIONAL EXPERIENCES:

Quality and Reliability Engineer IV, Applied Materials, Santa Clara, CA Oct 2017-present

design for reliability validation and improvement, qualifications for laser-related product

Reliability statistical modeling for Reliability Growth, MTBF, bottom-up and top-down apportionments

planning and driving reliability tests and reports, HALT, reliability life, CRAMS and ERAMS

driving failure analysis and corrective actions for field failures, manufacturing defects, and supplier issues

driving risk analysis using tool of FMEA and FMECA at system level and sub-system levels

Sr Reliability Engineer, Prysm, San Jose, CA Sept 2014-July 2017

Reliability modeling for video wall product reliability, MTBF, AFR, and Warranty Cost

Risk Analysis for product reliability and quality improvement using FMEA, Derating analysis

Reliability life tests for video wall product, and lasers and other sub-systems

Reliability improvement by implementation of corrective actions, failure analysis, field failure data analysis, and redundancy design, and ORT tests

On-going reliability (ORT) test setup, planning, data analysis and reporting

Failure analysis for failures from reliability lab tests and other field failures

Data analysis for reliability tests using Weibull models and other methods

Reliability Lab setup, maintenance, and upgrade

Staff Reliability Engineer, Neophotonics Corp, San Jose, CA May 2013-July 2014

completed about 30 qualification tests to qualify company's new telecom product

planned, setup, trouble-shoot for reliability lab, documented test procedures, trained test personnel

did failure analysis for minor and major failures happened during qualification tests, implemented corrective actions and improved product reliability

Driving suppliers for reliability data and reports for their products

FIT analysis based on vendor’s data and our own product field data

Principal Reliability Engineer, Emcore Corp, Newark, CA Aug 2011- May 2013

completed abut 20 qualification tests for company new telecom product launching

planned, managed test schedules, designed new test fixtures, trouble-shoot, hands-on run most of qualification tests, and test reporting

Analyzed failures from qual tests and improved product reliability

hands-on failure analysis for RMA returns of existing products, and reduced RMA backlog from 700+ units to 100 in a short time, and implemented corrective actions for product improvement

Drove suppliers for their failure analysis, corrective actions, and improvements

Sr Product Quality Engineer, Pacific Biosciences, Menlo Park, CA Sept 2009- Aug 2011

Initiated and implemented quality/reliability requirements for products and components

setting up quality lab for quality optical, electrical and mechanical inspections and tests

Driving/auditing suppliers for their quality improvements

Established and leaded daily MRB and RMA processes

Leading defect rates reduction for optical, electrical, and mechanical components

Sr. Reliability Engineer, Capella Photonics, San Jose CA May 2007- Aug 2009

Managed and implemented more than dozen of reliability projects

Planned and performed reliability and qualification tests, HALT and thermal shock etc

Modeled MTBF, FIT, Maintainability, and Warranty Cost

Drove FA and CA for customer returns and reduced return rate from 15% to 1%

ISO internal auditing and contributed to company ISO 9001 certification in 2008

NPI Project Manager, KLA-Tencor, San Jose, CA Jan 2004- Apr 2007

Developed new product introduction (NPI) plans for $20 million revenue product line.

Managed across-function teams for

Readiness and release of product drawings, process procedures, and BOM

Readiness of production staff, training, budget and facility, and production tools

Readiness of logistic and resources for field installation and services

Developed and implemented roadmaps for engineering verification tests, beta and pilot builds, cycle time and cost reduction, yield and quality improvement.

Hands-on experiences on lasers, optics, FA, and software installation and verification.

Staff Supplier Quality/Reliability Engineer, Avanex Corp, Fremont, CA Aug 2000- Jan 2004

Designing and coordinating reliability plans and tests for components per Telcordia standards

Supply quality engineering: AQL planning, incoming QA test setup, test trouble shooting, document test procedures, personnel training and test results reporting

supplier survey, evaluation, site auditing, and qualification.

A member of ISO internal auditing team and CCB board for ECO reviewing and approval

Staff R & D Engineer, MMC Technology, San Jose, CA Jul 1995-Aug 2000

Developed bench top laser texture system with green lasers and CO2 lasers.

Evaluation of lasers for laser texture: CO2, CW YAG, and Q-Switched YAG.

Process design, development, and optimization for laser texture, and tape burnish.

Metrology tool selection and application development from Wyko, Zygo, X-Ray, and AFM.

Process control (SPC), process trouble shooting for yield, Cpk, and throughput improvement.

University Teaching and Research, Fudan University, Shanghai, China 1986-1990

Teaching: University Physics in Optics, Electricity and Magnetism, and semiconductor labs.

One of three worldwide pioneers successfully made RF SQUID out of high Tc YBCO.

EDUCATIONS and TRAININGS:

Ph.D. in Physics, Southern Illinois University, Carbondale, Illinois.

M.Sc. in Physics, Fudan University, Shanghai, China.

B.Sc. in Physics, Fudan University, Shanghai, China

Six Sigma Green Belt; Project Management; ISO Internal Auditing

PROFESSIONAL MEMBERSHIPS:

American Society for Quality

American Physical Society

IEEE-Institute of Electrical and Electronics Engineering

JEDEC-Joint Electronic Device Engineering Council

PUBLICATIONS:

“Effects of Co and Y Substitution on Magnetic Properties of CeFe2 “, Xianfeng Zhang and Naushad Ali, J. Appl. Phys., 75(10), 7128(1994).

“Magnetization and Time Dependent Effects In ErCo3Ga2 Compound”, Naushad Ali and Xianfeng Zhang, J. Appl. Phys., 75(10), 7161(1994).

“Entropy Change at FM-AFM Transition in Intermetallic Compound Ce (Fe1-x Co x ) “, Xianfeng Zhang and Naushad Ali, J. Alloys and Compounds, 207/208, 294 (1994).

“Investigation of the Role of Ce in CeFe2 “, Xianfeng Zhang and Naushad Ali, J.

Alloys and Compounds, 207/208, 297 (1994).

“Unusual Magnetic Properties and Time Dependent Magnetization In ErCo3Ga2 “, Naushad Ali and Xianfeng Zhang, J. Alloys and Compounds, 207/208, 294 (1994).

“Magnetic Phase Transitions in Ce (Fe1-x Co x ) System “, Naushad Ali and Xianfeng Zhang, Int J. Mod. Phy. B, 7, 822 (1993).

“Magnetization and Thermoremanent Magnetization of Tb2Mo 2 O7 and Y2Mo 2 O7 Spin Glasses“, N. Ali, P. Hill, Xianfeng Zhang and Frank Wills, J. Alloys and Compounds, 181, 281 (1992).

“Magnetic Phases of the Itinerant Magnetic System Ce (Fe1-x Co x ) “, Naushad Ali and Xianfeng Zhang, J. Phys., Condense Matter, 4 L-351-L356 (1992).

“A High Tc SQUID for Measuring Susceptibility of High Tc Superconductive Thin Films”, J. W. Qiu, L. W. Zhou, X. F. Zhang, Z. M. Tang, Y. J. Qian and Z. Y. Hua, Appl. Surf. Sci., 48/49, 430-495 (1991).

“Physical Structure Effects on the Characteristics of RF-SQUID at 77K “, Xianfeng Zhang, Qui Jingwu et al, Solid State Commun., 74 (6), 479(1990).

“High Temperature Susceptometer and Its Applications”, L. W. Zhou, J. W. Qiu, X. F. Zhang et al, Physica B, 165-166, 86(1990).

“High Temperature Oxide Superconductor Double-Hole RF-SQUID”, Qiu Jingwu,

Xianfeng Zhang, J. Low Temp. Phys., 12, 289 (1990).

“High Temperature SQUID Susceptibility Measuring System “, Qiu Jingwu,

Xianfeng Zhang et al, Cryogenics, 30, Sept. Suppl., 920(1990).

“Properties and Applications of YBCO RF-SQUID”, J. W. Qiu, Xianfeng Zhang

Progress in High Tc Superconductivity-vol 22, P.76, World Sci., Singapore, 1990

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