Senior Process Engineer, IBS Coating Group

Job Details

• Title:
  
  Senior Process Engineer, IBS Coating Group
• Job Location s: US-FL
• Category: blank
• Type:
  Full Time

The primary responsibility of the Senior Process Engineer's (SPE) is to support Engineering activity within the Ion Beam Sputtering (IBS) Coating Cell of our Florida facility. The SPE will support both ongoing Production – with custom coating designs, fixtures and process troubleshooting – as well as R&D activities, to develop new processes and materials for advanced product requirements. This person will have ownership of the IBS Deposition Systems together with all associated metrology, having responsibility for its maintenance, upkeep, documentation and training.

IBS equipment is typically used for optical coatings that have hundreds of layers and run over multiple days, so reliable equipment and robust processes are paramount. The SPE will also be part of the Factory Quote Team, providing feasibility assessments and cost estimates for customer RFQs. A second area of responsibility will be to provide back‑up engineering support for the E‑Beam Coating area.

The SPE will use the principles of LEAN 6 and 6S to develop and execute a continuous improvement program for IBS production processes. This person is self‑directed and can work independently.

• Operate, maintain, troubleshoot and improve vacuum deposition equipment for IBS coatings.
• Train technicians in operation and maintenance of such equipment.
• Develop preventive maintenance schedules to avoid unscheduled downtime.
• Liaise with equipment manufacturer to implement software and hardware upgrades as necessary.
• Design substrate holders (fixtures) for both routine shapes and custom parts.
• Use commercial software to design complex multilayer coatings for demanding specifications, including laser damage, polarization and GDD control for Ultrafast applications.
• Characterize materials for optical properties to a high degree of accuracy and evaluate their variation and evolution over time.
• Specify and optimize metrology to measure critical coating performance: R, T, GDD, Loss, Absorption. Train technicians in accurate operation of this equipment.
• Conduct experiments to evaluate Cp and Cpk for IBS processes using Lean Six Sigma, and DOE methodologies.
• Develop a Critical Materials List with primary and secondary suppliers.
• Supervise the creation of routings, SOP’s, WI’s, etc.
• Review RFQs with the IBS Quote Team and either complete or reassign to other members of the department.
• Specify new equipment and tools to increase capability and/or capacity.
• Based on need, become proficient in equipment and processes outside of area‑of‑focus.
• Generate detailed reports for both custom production work (FAIs) and R&D activity.
• Participate in bringing new technology or processes from Pilot to Production.
• May be required to use shop and power tools to modify parts or equipment.
• Comply with federal, state, and company policies, procedures, and regulations.

To perform this position successfully, an individual must be able to perform each essential function satisfactorily. The requirements listed below are representative of the knowledge, skill and/or ability required. Reasonable accommodations may be made to enable individuals with disabilities to perform the essential functions.

• In depth understanding of High Vacuum Systems, associated pumps, sub‑assemblies and control equipment.
• Familiarity with vacuum diagnostics using residual gas analysis and leak detection.
• Working knowledge of IBS components such as ion sources, grids, power supplies and target assemblies.
• Understanding of Broad Band Optical Monitoring (BBOM) principles.
• Good working knowledge of Opti Layer or equivalent commercial thin film design software.
• Familiarity with various models for the characterization of optical materials, such as Cauchy, Sellmeier, and Lorentz.
• Ability to use software for reverse engineering to assess thickness errors from spectral measurements.
• Familiarity with standard techniques to improve non‑uniformity, such as chamber geometry and shadow masking.
• Working knowledge of advanced metrology equipment, such as spectrophotometers,…