Yield Engineer for the introduction of the first Foundry products to Fab24.I studied the process documentation for our new process. I put together a unified but easily updated document showing each step of the process and the purpose of each step. I shared this with my colleagues and it became a focus for collaboration. The work of the group was accelerated and facilitated by the production of a single document on process flow. Other groups asked us to share this document.New products going into volume production in Intel Fabs require ‘certification’. I formulated acceptance criteria and agreed them with stakeholders. I collected data and completed statistical analysis for ~150 parameters. I investigated any signals or anomalies. I presented data to a review meeting of senior managers and engineers. The product certification was approved and my analysis was key to this.I recognised the need for process step data. I initiated and chaired a working group across multiple functions. We agreed on a standard, we divided the work, we quickly implemented the solution. Process step data is now available for almost 100% of steps across multiple sites and databases. The system fully functional and is actively used and updated.Our customer wanted regular reports of Yield data. This was a new customer in a new business. I wrote scripts to extract the data and summarise it in the way that the customer required. I wrote and fine tuned a report to fully satisfy the customer. I automated the report. The customer now receives a regular report that gives them the data they want and that they can trust.

Introduced Lean Six Sigma, trained and mentored many employees, many millions of dollars saved.I recognised the need for a Lean Six Sigma (LSS) at the Intel Leixlip site. Many Engineers and others recognised the need for cost reduction activities but lacked a methodologyNo LSS program existed and little was known about LSS. Intel had a small scale LSS program limited to the US.Working with a Black Belt from the US I held multiple 2 week Green and Black Belt courses. I mentored around 100 candidates and helped them to achieve certification. I promoted the program and consulted with many people to encourage participation. I explained the program and got the support of senior managers. I helped other sites in the UK and US to establish LSS programs by teaching and mentoring at those sites.We established a Lean Six Sigma program across the site. This included 2 Fab organisations as well as support organisations such as Finance, Materials and Facilities. Many millions of euro saved and more than 100 people were certified with Green Belts. I established a network of certified Black Belts.

Data Analysis and interpretation of yield and manufacturing data.Data extraction and cleaning.Analysis of data using statistical and graphical methods.Working with process owners to improve and optimise many diverse stages of the fabrication process, combining knowledge of the process with product knowledge and wafer test dataMentoring and training new Yield Analysis Engineers and setting expectations around analysis and process improvement activities.Generating and managing a yield improvement roadmap for the products that I owned.Working with wafer test (sort) program owners to improve the wafer test process and protect customers.Finding problems using statistics and explaining the analysis to engineers and managers.

I introduced FDC to Fab24. I went to other Intel Fabs and learned about the system implementation and integration. I trained hundreds of users in the use of the system. I worked with IT to establish a reliable system and monitoring methods. I developed KPIs and a reporting system and reported to senior management on progress and coverage rates. Fab24 has a comprehensive, resilient FDC system with all equipment types being monitored and controlled. Yield loss is avoided at every step in the process.

I extracted and analysed manufacturing data for the product I owned. The product was already yielding well so marginal improvements were important. I used this analysis to maintain and improve yield.

Provided statistical consulting to all areas of the business supporting process improvements, regulatory compliance and statistical process control. Resulted in properly designed studies and useful experimental results.Reviewed the statistical methods and conclusions for process change proposals. Participated in multi-factory review bodies as a statistical adviser and reviewer. Safeguarded the factory from unwarranted changesProvided statistical consulting to ‘task forces’ with the intention of understanding previously unknown relationships between factors in the process. For example the relationship between atmospheric pressure and deposition processes. Resulted in rapid understanding of root causesTrained Engineers and Scientists in the use of statistical thinking, hypothesis testing, design of experiments, data visualisation and statistical process control. Developed and adapted training material. Resulting in increased skills for hundreds of employees.Leading and advocating statistical process control(SPC) programme.Leading SPC technology transfer.Developing reports including coding in JSL, SQL and SAS.Reviewing and setting standards in SPC operations.Teaching and consulting on the use of statistical methods including hypothesis testing, probability, reliability methods, Design of Experiments (DoE) and Response Surface Methodology (RSM).Designing and analysing experiments.

Teaching Quality Management module to students on the Masters in Engineering Management course. The module covers applied statistics and statistical process control.

Analysing customer behaviour and building predictive models for use in marketing campaigns. Modelling Mortgage redemptions in a rapidly changing banking market. Explaining customer behaviour and models to boards of financial institutions.

Investigating and developing new manufacturing techniques in surface mount technology (SMT) and mechanical assembly.

During my time as a Quality Engineer at Motorola I worked on the following areas:Quality improvement projects in two way radio manufacturing plant, working on surface mount technology (SMT), mechanical assembly and radio frequency (RF) testing.Managed and operated a quality reporting system that provided weekly information to the business unit.Quality system preparation and auditing to both ISO9000 and Motorola Quality System Review (QSR). QSR is an excellence standard covering all aspects of management, engineering and production.Quality system auditing in suppliers and joint venture partners.Delivering Six Sigma training to the general population and to Six Sigma Belt candidates.Failure Mode and Effect Analysis of new products and processes, both as a team facilitator and as a content expert.Working directly with customers on technical resolution of field issues.

Process improvement.Introduction of cellular manufacturing.Technology transfer both into and out of the organisation.