Senior Manufacturing Process Engineer
Improved coating surface quality for Digital mirrors from a defect density of 0.5 defects / ft2 to 0.025 defect density over a time period of 3 months.
- Brought sputtering machine back to standard hardware configuration and operating principles. This allowed the lines speed to be increased by 15% for one product and set the stage to increase the though put of second product by 30%.
- Using Root Cause Analysis identified hardware changes to increase machine uptime by 20%
- Improved cleaning efficiency with improved Flat plate washer operational protocol. Implemented process controls to eliminate down time and reduce filter costs.
- Enabled the coating of Digital Mirror at Contract Manufacturer (CM) by implementing known cleaning technology and clean room environment as it relates to inline coaters (Previously developed at MAC).
- Identified the two top defect categories of CM and implemented process changes to significantly reduce the top defect form 15% to 1% and the second defect from 5% to 3%.
- Qualified a new protective tape for the digital mirror industry which reduced tape costs by $0.015 per square foot. The tape was also an ergonomic advantage because it is easy to remove (reduces risk of carpal tunnel injury)
- Found root cause of latent transparent defect that occurred after the product reached the customer. Sulfur and Chlorine particles were being trapped under the protective tape during manufacturing mirror product. Eliminated the defect by improving manufacturing protocol and equipment.
- Specified and purchased 74" width FPW during initial installation of inline sputtering machine in about 1995.
- Provided Technical Support to sales