Process Six Sigma

Success Through Strategic & Goal-Oriented Process Improvement

ENGINEER - PROCESS IMPROVER - TEAM LEADER

Conquering process and operations challenges for over 11 years with a proven record of accomplishment: double-digit percent schedule reductions, six-figure cost savings, technology startup and ramp leadership, and quality risk mitigation. Successfully navigates cross-site and cross-functional teams through high priority initiatives leveraging effective leadership tactics, managing key relationships, and building strong systems to achieve impactful results.

Employs Lean Six Sigma principles to generate customer-focused objectives, standardize value-added solutions, eliminate process waste, and drive continuous improvement. Delivers cost-effective advancement to business process efficiency in fast-paced, dynamic environments.

AREAS OF EXPERTISE - KEY ACHIEVEMENTS

Model-based Problem Solving Lean Process Improvement Technical Training

Quality Systems Analysis Operations Streamlining Presentation/Documentation

Process Change Management Project Management Team Development

Statistical Process Control Cost Analysis & Reduction Supplier Management

• Designed an Effective Quality System visual management tool used by the QSM to identify and resolve potential ISO9000 findings prior to certification audits.

• Successfully revived a critical risk mitigation project and drove on-time completion to avoid costly equipment failures.

• Chaired a multi-site Mission Based Team of integration, process, and quality engineers that developed a containment strategy for an undetectable process defect to alleviate a major escape and reliability concern.

• Directed a cross-site engineering effort to achieve $400k in annual commodities usage reduction.

• Co-wrote and managed a 320-hour advanced technician training and certification program.

PROFESSIONAL EXPERIENCE - ACCOMPLISHMENTS

Intel Corporation 2000-Present

Worldwide leader in semiconductor design and manufacturing for all electronics market segments, specializing in High-volume Manufacturing Excellence through Lean Integration and Total Quality Management.

Progressed through a series of increasingly challenging and diverse roles within Photolithography Process Engineering at multiple facilities including international assignments, a joint venture, and a Lean Journey.

Intel Massachusetts (Hudson, MA) - 200mm CPU and I/O chipset wafer Fab

Process Improvement Expert, 2008-Present

Capacity Project Leader, 2003-2006

Executed high-level initiatives to drive down commodities and capital spending while improving EOL product yield. Fostered a culture of Lean and Team Empowerment as an advocate for standardization and waste elimination.

• Core member of a Task Force that developed a solid process for defining the current and ideal state any system. Assessed 2 primary factory quality systems, proposed solutions to close all gaps identified - proposal accepted.

• Streamlined an equipment risk project by cutting out non-value added tasks and redefining information and data flows. Generated 75% reduction in durations which enabled weekly performance to planned schedule.

• Standardized data collection and analysis of yield correlation tests to enable immediate failure response and early detection based on trends. Propagated the system as the new standard for all other tests.

• Consolidated an equipment upgrade procedure from 48 to 4 hours, saving $25k in labor cost. Procured reuse assemblies from multi-site inventories to negate all materials cost ($75k per upgrade).

Partnered with I.E. and Construction trades to increase capacity of a critical factory constraint. Collaborated with Training and Manufacturing to upskill technical teams to support increased maintenance and production activities.

• Managed a $1.2M parts and labor budget for reuse equipment installations. Leveraged industry connections to obtain $125k of replacement parts and negotiated over $100k in equipment supplier labor price reductions.

• Generated 60% schedule reductions through process mapping , value-added focus, and hands-on technical leadership. Implemented layout and base build plan modifications to avoid costly change orders.

• Developed, co-wrote, and managed implementation of a 320-hour program designed to train and certify advanced technicians on complex repairs to support ramping up volume, without increasing expensive supplier headcount.

imFlash Technologies (Lehi, UT) - 300mm NAND/Flash product Joint Venture between Intel and Micron

Joint Venture Technical Resource, 2006-2008

Volunteered and successfully led a team of 12 process and equipment engineers through a record-breaking pace start-up and production ramp. Built a solid working relationship with manufacturing personnel to enable highly productive problem solving and goal oriented output.

• Kicked off and facilitated the only mid-shift engineering "check-ins" - received rave reviews from team members regarding balance of workloads and cohesive prioritization.

• Mentored two Process Leads as the go-to project experts and first points of contact for manufacturing support.

• Trained new engineers - including two technology transfer seeds from the Singapore site - on SPC, cleanroom operations, and analysis of process characterization data to qualify production tools.

• Encouraged and recognized safe behavior during management passdowns and team meetings.

Intel Oregon/PTD (Hillsboro, OR) - 200mm Process Technology Development and Manufacturing

Intel Israel and Intel Ireland (Qiryat Gat, IS and Leixlip, IR) - 200mm high-volume wafer Fabs

Process Technology Transfer Assignments, 2001-2002

Traveled to high-volume facilities to train on process technologies, products, and equipment. Transferred all key learnings, documentation, and knowledge to Hudson, MA to start-up and ramp new processes.

• Led an engineering module team to 100% progress against schedule transferring all process control setups, QA/QC best known methods, equipment installation designs, and maintenance procedures.

• Achieved best-in-class turn-around times for New Product Introductions as a NPI Team member.

• Trained and certified the Hudson, MA 7x24 manufacturing and equipment maintenance teams.

EDUCATIONAL PROFILE

Rensselaer Polytechnic Institute (Troy, NY)

B.S. Materials Science and Engineering, 2000

Professional Development

• Lean Six Sigma Overview Course / "What is Lean Six Sigma?" (George, Rowlands, Kastle - 2003)

• Business Continuity Course / Business Process Efficiency and Effectiveness Training

• Introduction to Model-based Problem Solving

• Waste Elimination Course and Training

• Factory Physics / Manufacturing Excellence Overview Course

• Proficient with Microsoft Office Suite: Word, Excel, PowerPoint, Schedule

• Manufacturing Software: MES, Workstream, eSpeed, MTSPC, SPC++, Exceed, DOS, CuSum, APC,

Sharepoint, Documentum, GeRM, RCT

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