Thomas S. Email & Phone Number

San Diego, California, United States

Lehi, Utah, United States

⏹️ Exhibited engineering aptitude by fully owning several photo 248nm and 365nm processes one month ahead of schedule and becoming the area champion of automated process control.⏹️ Introduced new area methods, procedures, and flow charts around APC methodology to improve performance and reduce error notifications. My efforts eliminated 2 major APC-caused process interruptions, and reduced error notification frequency by 84%.⏹️ Compiled several JMP JSL scripts to accelerate data analysis, saving an average of ~15 minutes of engineering time per statistical process control chart data pull.⏹️ Troubleshot and resolved via fill voiding defects by facilitating several vendor and cross-functional meetings. My efforts, organization, and data collection went above and beyond, revealing the same underlying systemic problem at other TI fabs. The preventive action eliminated defects from 100% of vias impacted to 0%. The insights are planned to be shared in the next Utah Technical Symposium.⏹️Improved CD SPC process capability of a problematic 248nm process to meet strict automotive standards by leading a cross-area team, utilizing IDEA problem-solving methodology, and collaborating with TI fabs + foundries worldwide. I identified the SPC variation to substrate oxidation caused by product re-works and idle time. I improved the performance without introducing a costly BARC film or extra traveler step by utilizing APC, queue times, smart sampling, and attribute-based processing parameters.⏹️Designed and executed a conversion qualification path for a new, more soluble resist to eliminate the risk of a drainage block with the potential for a fab shutdown. I conducted a comprehensive comparison study of DSIMS analysis, cross sections, wafer uniformity, overlay, alignment, and electrical data to ensure no impact on product quality. Proactively, I included checks to downstream processes so all affected parties could quickly source any possible unexpected variation.

Lehi, Utah, United States

Focusing on improving yield of product and performance of tools in a semiconductor manufacturing fab. I was part of the physical vapor deposition, ion implantation, and rapid thermal processing team (PIR). I monitored processes running on advanced tools from several prominent semiconductor tool manufacturers like AMAT, ULVAC, and Axcelis. I would ensure the tools were up to specifications to maintain peak product quality by analyzing SPC charts and other metrology data. Daily I would troubleshoot equipment and adjust/tweak various processes.I use my engineering methodology to fix problems by proactively or immediately identifying the issue, conducting research and defining possible causes, evaluating the probable root cause through well-reasoned tests, and finally acting on a solution to the problem, all the while communicating and sharing the knowledge gained.Resume Bullets:⏹️Presented an overview of the PVD process in the semiconductor industry to the entire site engineering team.⏹️Promoted within one year to E2 through demonstrated ability to work in stressful high-risk scenarios with cross-functional teams of engineers and technicians to recover thousands of dollars worth of product. ⏹️ Implemented and documented over 90 area improvement items in one year, including procedures, SOPs, and trainings, resulting in improved efficiency and ISO compliance.⏹️ Utilizing OPPM style for project management, successfully replaced an obsolete fab tool alarm system within the PVD/IMP/RTP area in half the expected time.⏹️ Developed and implemented a program to increase the skillset of all shift engineers, complete suspended projects, improve area communication, and improve knowledge sharing, resulting in a more valuable workforce.⏹️ Implemented equipment down state notifications that improved tool uptime by 1-2 hours per down event, resulting in hundreds of saved tool hours over a year.

The purpose of my project was to design a functionally graded NbC, a new material, with carburization techniques.⏹️ Provided proof of concept for first-ever NbC carburization with desired cutting/drilling tools properties.⏹️ Composed extensive notes and SOPs over 3 years to clearly disclose research, methods, and safety concerns.⏹️ Hydrogenated niobium powder for planetary milling and mixing of Nb in NbC to fabricate zeta phase NbC⏹️ Performed numerous experiments and characterization tests with extensive troubleshooting (i.e., milling, hydrogenation, PSD, polishing, etching, fracture toughness, SEM, EDS, XRD, hardness tests, and carburization).⏹️ Months of power metallurgy experience, manufacturing solid ASTM standard specimens from base powder constituents. Requiring extensive DOE, processing, characterization, qualification testing, and design validation.⏹️ Research paper publication in draft for functionally graded NbC properties and applications in cutting tools.

Greater Salt Lake City Area

⏹️ Wrote research proposal that Undergraduate Research Opportunities Program awarded with $3,200 over 100s of other applicants⏹️ Competed in Get Seeded and Adventure Gear Fest 2017 winning 1st place in both receiving ~$7,000 in prizes.⏹️ Developed a sustainable, safe, and transparent dip coated anti-fog layer for polycarbonate using a “home-made” 3-D printed robot arm to help in manufacturing.⏹️ Oversaw the entirety of project management, research, development, documentation, and completion over the course of 4 months with 3 colleagues.

Lehi, Utah

Focusing on improving yield of product and performance of tools in the physical vapor deposition and ion implantation areas. I monitor processes that run on tools and ensure that they are up to specifications by trouble shooting equipment and adjusting/tweaking processes. I use my materials science knowledge to identify common film property imperfections, analyze metrology data, and for material characterization. I use my engineering methodology to work on fixing problems by proactively or immediately identifying the issue, conducting research and defining possible causes, then evaluating the probable root cause through controlled well reasoned a tests, and finally acting on a solution to the problem all the while communicating and sharing the knowledge gained.